Lattner Boiler Company Scotch Marine Steam & Hot Water Boilers
INSTRUCTION MANUAL
December 2005
Lattner Boiler Company 1411 9th St. SW Cedar Rapids, IA 52404 T: (800) 345-1527 F: (319) 366-0770 E: [email protected] www.lattnerboiler.com
LATTNER BOILER COMPANY Scotch Marine Boiler Operations Manual ______
Index
Section I: General Description Page 3
1. Boiler Design ………………………………………………………………..………………………………….3 2. Boiler Connections ………………………………………………………………..………………………………….4 3. Boiler Trim ………………………………………………………………..………………………………….4 4. Fuel Burning System ………………………………………………………………..………………………………….5 5. Fuel/Air Control ………………………………………………………………..………………………………….5 6. Gas/Fuel Train ………………………………………………………………..………………………………….6 7. Control Panel ………………………………………………………………..………………………………….6 8. Factory Tests ………………………………………………………………..………………………………….7 9. Nameplates & Stamping ………………………………………………………………..………………………………….7 10. Guarantees ………………………………………………………………..………………………………….7
Section II: Installation Page 8
1. Unloading ………………………………………………………………..………………………………….8 2. Rigging ………………………………………………………………..………………………………….8 3. Placement of Boiler ………………………………………………………………..………………………………….8 4. Combustion Air ………………………………………………………………..………………………………….8 5. Stack ………………………………………………………………..………………………………….9 6. Steam Outlet ………………………………………………………………..………………………………….9 7. Blowdown Piping …………………………………………………………….…………………………………...10 8. Safety Valve …………………………………………………………….…………………………………...11 9. Gas/Fuel Train Piping …………………………………………………………….…………………………………...11 10. Boiler Feed Systems …………………………………………………………….…………………………………...12 11. Electrical Connections …………………………………………………………….…………………………………...13 12. Before Firing the Boiler …………………………………………………………….…………………………………...13 13. Pressuretrols: Controller & Limit …………………………………………………………….…………………………………...14 14. Firing the Boiler …………………………………………………………….…………………………………...15 15. Boil Out Recommendations for New Boilers …………………………………………………………….…………………………………...16 16. Standard Maintenance Items …………………………………………………………….…………………………………...16 17. Water Quality Limits for Lattner Boilers …………………………………………………………….…………………………………...17
Section III: Boiler Care & Maintenance Page 18
1. Daily Procedures …………………………………………………………….…………………………………...18 2. Weekly Procedures …………………………………………………………….…………………………………...18 3. Monthly Procedures …………………………………………………………….…………………………………...18 4. Annual Procedures …………………………………………………………….…………………………………...19 5. Care of Idle Boilers …………………………………………………………….…………………………………...19 6. Care & Service of Boiler Tubes …………………………………………………………….…………………………………...19 7. Boiler Tube Replacement …………………………………………………………….…………………………………...20 8. Handhole Plate Removal & Replacement …………………………………………………………….…………………………………...21 9. Sight Glass Removal & Installation …………………………………………………………….…………………………………...22 10. McDonnell Miller Servicing …………………………………………………………….…………………………………...23 11. Warrick Relay Replacement …………………………………………………………….…………………………………...24 12. Auxiliary Low Water Cut-Off Probe Cleaning …………………………………………………………….…………………………………...24
Section IV: Troubleshooting Page 25
1. Normal Operation …………………………………………………………….…………………………………...25 2. Basic Service Tools …………………………………………………………….…………………………………...25 3. Before You Begin …………………………………………………………….…………………………………...25 4. Troubleshooting …………………………………………………………….…………………………………...26
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Lattner Boiler Company 1411 9th St. SW Cedar Rapids, IA 52404 Telephone: (800) 345-1527 Fax: (319) 366-0770 Web: www.lattnerboiler.com
LATTNER BOILER COMPANY Page 3 Scotch Marine Boiler Operations Manual ______
Section I: General Description
WARNING: All installation procedures must be followed completely by a competent installer familiar with boilers and boiler accessories.
CAUTION: Read and follow all instructions before installing any boiler equipment. All cover plates, enclosures and guards must be maintained and in place at all times, except during maintenance and servicing.
1. Boiler Design Lattner horizontal firetube boilers are designed as three pass scotch marine dry back boilers with integral furnaces and convective heat transfer firetubes. The furnace and heat transfer tubes are completely submerged beneath the normal operating water level. The total heating surface is based on 5 square feet per boiler horsepower (output). All Lattner firetube boilers are built in accordance to the appropriate ASME Code for low pressure steam, high pressure steam, low pressure hot water, or high pressure hot water.
1.1. Gas Flow The tube design of Lattner firetube boilers provides three pass longitudinal heated gas flow direction, ensuring maximum linear heated gas travel and heat transfer. Low maintenance, durable refractory lined steel baffles are incorporated for heated gas flow direction between the second and third passes. Symmetrical tube design and layout provides equalized flow of heat into each tube from the furnace and successive gas passes, ensuring high efficiency.
1.2. Water Circulation All feedwater and water return connections enter the side of the vessel below the water line. By directing the make-up water below the water line of the boiler, the possibility of collapsing steam bubbles is eliminated allowing the boiler water to circulate naturally.
1.3. Tubes Boiler tubes are a minimum of 2-1/2” OD, with a wall thickness of 0.105”. Each tube is attached to the front and rear tube sheets through a rolling and beading process. High pressure boiler tubes are additionally seal welded at the entrance to the second pass.
1.4. Furnace The furnace or combustion chamber is centrally located within the pressure vessel. It consists of a single cylindrical tube strength welded to the front and rear tube sheets. It is symmetrical in layout, assuring a balance flow-circulating pattern under all load conditions.
1.5. Outer Casing (Jacket) The removable outer casing or jacket is fabricated of 22 gauge galvanealed steel panels supported by 2” thick fiberglass blanket insulation. This arrangement provides a skin temperature near ambient conditions.
1.6. Fireside Inspection Front and read doors (davited or hinged on 60 horsepower and larger) are furnished for tube inspection and cleaning of the second and third passes. An inner rear furnace access door is available for furnace inspection, eliminating the need to remove the burner.
1.7. Water Side Inspection For visual inspection of the water side internals and tube surfaces six 3” x 4” handhole inspection plates are provided. A 12” x 16” man hole is furnished for upper vessel inspection on boilers 80 horsepower and larger.
1.8. Flame Observation Port For visual inspection of the pilot and main flame ignition, there are two flame observation ports. One flame observation port is provided integral to the burner and one is located in the rear furnace access door.
1.9. Boiler Lifting Lugs Two lugs are provided to facilitate lifting and rigging the boiler into place. These lugs are located on the top centerline of the pressure vessel.
1.10. Boiler Base A structural steel welded base is provided upon which the pressure vessel is placed. The minimum height of the structural base is 4” and the boiler is attached to the base at four points (legs). A short base extension may be incorporated to provide mounting for a separate oil pump or oversize control panel.
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Lattner Boiler Company 1411 9th St. SW Cedar Rapids, IA 52404 Telephone: (800) 345-1527 Fax: (319) 366-0770 Web: www.lattnerboiler.com
LATTNER BOILER COMPANY Page 4 Scotch Marine Boiler Operations Manual ______
2. Boiler Connections
2.1. The following items are factory installed in accordance with the ASME Code:
2.1.1. Steam Connection The supply connection is located on the top centerline of the boiler and is either threaded or an ANSI flange design. The operating and design pressure of the boiler, in accordance with the ASME Code, determines the pressure rating of the flange.
2.1.2. Boiler Blowdown or Connection Drain Boilers under 80 horsepower have one threaded fitting on the bottom centerline at the rear of the pressure vessel. Boilers 80 horsepower and larger have two threaded fittings on the bottom centerline at the rear of the pressure vessel.
2.1.3. Surface Blow-Off A tapping is provided in the vessel near the normal water level line for connection to a manual or automatic surface contaminant removal system or metering valve.
2.1.4. Feedwater Make-Up A tapping is provided on each side of the pressure vessel for connection to the make-up and/or condensate return.
2.1.5. Exhaust Gas Vent (Stack) The connection for the stack or breaching is located at the rear on the top centerline of the boiler. This is a flanged connection, with the opening in accordance with the nominal dimension and rating sheets. A tapping is provided for a stack temperature probe or thermometer.
3. Boiler Trim The following are factory installed standard trim and control items. Trim items are supplied in accordance with the ASME Code. Controls are UL listed and comply with ASME CSD-1 requirements.
3.1. Safety Relief Valve(s) In compliance with the ASME Code, steam boiler pressure relief valves are provided. Size and quantity determined by the valve setting, valve capacity, and the ASME Code. These are shipped loose to prevent possible damage during shipment.
3.2. Water Column Furnished complete with gauge glass, gauge glass drain valve, gauge glass isolation valves, column try-cock tappings, column drain valve, minimum of 1” equalized piping and crosses for inspection and clean-out.
3.3. Low Water Cut-Off To prevent burner operation whenever a low water condition occurs, a single pole double throw float operated level switch is furnished in the water column. Cut-off is wired in series to the burner combustion safeguard control.
3.4. Pump Control A single pole single throw float level switch is provided in the water column for ON/OFF operation of a feedwater make-up pump, starter, or valve.
3.5. Auxiliary Low Water Cut-Off An additional control, separate from the primary low water cut-off control is provided to prevent burner operation if a low-low water condition exists. This device is an internal probe control located on the top centerline of the pressure vessel.
3.6. Steam Pressure Gauge or Temperature/Pressure Gauge 3-1/2” dial pressure gauge is furnished as standard. The range of the gauge will be in accordance with the safety valve setting, based on 1.5 times the valve setting for high-pressure units, and 2 times the design pressure of low-pressure units.
3.7. Pressure or Temperature Controls
3.7.1. On/Off Operation On/Off operation is available on boilers 10 through 20 horsepower. On/Off operation requires two pressure or temperature controls, a “Limit” and a “Controller”. The “Limit” determines the pressure at which the burner will cycle OFF. The “Controller” (with differential) determines the pressure at which the burner will cycle ON. See Section II for control setting directions.
3.7.2. Low/High/Off Operation Low/High/Off operation is available on boilers 10 through 100 horsepower. Low/High/Off operation requires two pressure or temperature controls, a “Limit” and a “Controller”. The “Limit” determines the pressure at which the burner will cycle OFF. The “Controller” (with differential) determines the pressure at which the burner will cycle ON. See Section II for control setting directions.
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Lattner Boiler Company 1411 9th St. SW Cedar Rapids, IA 52404 Telephone: (800) 345-1527 Fax: (319) 366-0770 Web: www.lattnerboiler.com
LATTNER BOILER COMPANY Page 5 Scotch Marine Boiler Operations Manual ______
3.7.3. Low/High/Low Operation Low/High/Low operation is available on boilers 10 through 100 horsepower. Low/High/Low operation requires three pressure or temperature controls, a “Limit”, a “Controller”, and a “High Fire” device. The “Limit” determines the pressure at which the burner will cycle OFF. The “Controller” (with differential) determines the pressure at which the burner will cycle ON at low fire. The “High Fire” device determines the pressure at which the burner cycles ON at high fire. See Section II for control setting directions.
3.7.4. Modulating Operation Modulating operation is available on boilers 10 through 200 horsepower. Modulating operation requires three pressure or temperature controls, “Limit”, “Controller”, and “Modulating” devices. The “Limit” determines the pressure at which the burner will cycle OFF. The “Controller” (with differential) determines the pressure at which the burner will cycle ON. The “Modulating” device regulates the rate at which the burner will fire (any rate between low and high fire). See Section II: Installation for control setting directions.
4. Fuel Burning System The factory-assembled boiler is furnished with an UL approved and labeled fuel burning forced draft system. The system is mounted and wired integral with the front head of the boiler.
4.1. Burner Type The burner is a forced draft (power burner) design, high radiant multi-port type for LP or Natural gas and mechanical pressure atomizing type for No. 2 fuel oil. The burner can be equipped to burn natural gas, oil, or a combination can be provided to manually switch between gas and oil fuels. The burner is not designed to burn both fuels simultaneously.
4.2. Burner Operation The burner is designed to operate one of four modes:
4.2.1. On/Off With the On/Off method of operation, the burner shuts off when the pressure reaches the set point of the “Controller” device. The burner turns on again when the differential set point on the “Controller” is exceeded.
4.2.2. Low/High/Off With the Low/High/Off method of operation, the burner turns ON at low fire and shuts off when the pressure reaches the set point of the “Controller” device. The burner turns on again when the differential set point on the “Controller” is exceeded.
4.2.3. Low/High/Low With the Low/High/Low method of operation, the burner fires on high fire until it reaches a predetermined pressure range. Once it reaches this range, the burner continues to fire on low fire as necessary until the boiler’s pressure drops below this range (in the case of a large steam demand) when the burner fires again at high fire.
4.2.4. Modulating With the modulating method of operation, the burner fire rate is determined by the current demand. The burner modulates or throttles the input gas relative to constantly changing pressure requirements as determined by the “Modulate” pressure control.
4.3. Ignition and/or Pilot For oil-fired units, a 10,000 volt ignition transformer is furnished for direct spark ignition. Gas-fired units are equipped with a spark- ignited gas pilot assembly. The gas pilot assembly includes a pilot gas cock, gas pressure regulator, ignition transformer, pilot safety shutoff valve, and gas pilot pressure gauge.
4.4. Forced Draft Fan An integral fan assembly direct connected to a NEMA-1 foot mounted fan motor supplies the required combustion air. As standard, the fan motor is an open drip-proof (ODP) high efficiency type operating at 3600 RPM.
4.5. Air Proving Switch An air pressure-sensing switch is mounted on the burner to prevent burner operation if sufficient air is not available for proper combustion or pilot ignition.
5. Fuel/Air Control The control of combustion air is managed with an integral inlet air damper operating as follows:
5.1. On/Off With the On/Off method of operation, the burner air damper is mechanically fixed for the correct combustion air to fuel ratio for on/off firing.
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Lattner Boiler Company 1411 9th St. SW Cedar Rapids, IA 52404 Telephone: (800) 345-1527 Fax: (319) 366-0770 Web: www.lattnerboiler.com
LATTNER BOILER COMPANY Page 6 Scotch Marine Boiler Operations Manual ______
5.2. Low/High/Off With the Low/High/Off method of operation, the burner air damper is mechanically coupled to the damper motor and fuel input control valve(s). A Low/High/Off position control regulates the position of the damper and fuel input control valve(s) for either low fire input or high fire input.
5.3. Low/High/Low With the Low/High/Off method of operation, the burner air damper is mechanically coupled to the damper motor and fuel input control valve(s). A Low/High/Low position control regulates the position of the damper and fuel input control valve(s) for either low fire input or high fire input.
5.4. Modulating With the modulating method of operation, the burner air damper is controlled with potentiometer type positioning controls regulate the position of the damper and fuel input control valve(s) which are mechanically linked together. Integral switches of the damper motor provide proof of maximum airflow purge prior to ignition, and the safe start position at low fire, for pilot ignition.
6. Gas/Fuel Train The burner is equipped with factory mounted fuel safety control and safety shut-off valves for either gas fuel or oil fuel. Each fuel piping assembly is equipped with the following:
6.1. Gas Assembly Boiler base rail mounted, piped and wired gas piping assembly, consisting of main gas pressure regulator, safety shutoff valves, manual shutoff cocks, fuel input control valve, and gas pressure interlocks in accordance with the latest UL and CSD-1 requirements.
6.2. No. 2 Fuel Oil Assembly For burners equipped to burn fuel oil, the boiler is equipped with dual safety shutoff valves, manual shutoff valve, oil discharge filter, and an oil pump. The oil pump is direct driven from the fan motor assembly and is used for mechanical pressure atomization of the fuel oil for proper combustion. This pump requires twice the burner firing delivery for suction line sizing.
A separate oil pump assembly with an integral oil pump motor can be furnished as an option and will be mounted on the boiler base extension or shipped loose for field installation by others. For units with this option, a Low Oil Pressure Safety Switch is provided.
7. Control Panel A NEMA enclosed control panel is mounted integral to the burner or as an independent bracket mounted unit on the boiler base rail. This panel contains as a minimum the following components:
7.1. Combustion Flame Safeguard Control This solid-state control provides for safe start sequencing of the burner from start-up, run, to safety shutdown. A flame-sensing device of the lead-sulphide scanning principle is furnished.
7.2. Burner On/Off Switch A burner On/Off switch is provided to interrupt control power to the 120 volt control circuit. This switch does not disconnect the main power source.
7.3. Control Circuit Transformer For burners above 2.5 million BTUs/Hr input (60 horsepower), a step-down transformer from the 3-phase power supply is furnished to provide the 120 volt single phase supply to the control circuit.
7.4. Indicating Lights Indicating lights are mounted in the control panel door or switch ledge for “Load Demand”, “Power On”, “Fuel Valve On”, “Low Water”, and “Flame Failure”.
7.5. Manual/Auto Switch For service checking and start up, a damper positioning switch is provided to allow the burner to be controlled via a manual positioning control in lieu of the automatic positioning device. This switch is furnished on Low/High/Off, Low/High/Low, and Modulating boiler/burner packages.
7.6. Main Flame Potentiometer The main flame potentiometer is provided as a means to check the burner combustion process or base load the burner in a multiple boiler installation. This control is furnished on units with modulating burners only.
7.7. Wiring & Controls All devices and wiring are provided in accordance with the latest UL/NFPA 70 requirements. Each device is UL listed or recognized and bears the UL label and/or stamp.
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Lattner Boiler Company 1411 9th St. SW Cedar Rapids, IA 52404 Telephone: (800) 345-1527 Fax: (319) 366-0770 Web: www.lattnerboiler.com
LATTNER BOILER COMPANY Page 7 Scotch Marine Boiler Operations Manual ______
8. Factory Tests
8.1. Pressure Vessel The boiler is subjected to an ASME certified hydrostatic pressure test. This test, in accordance with the requirements of the ASME Code for Section IV Heating Boilers or Section I Power Boilers, is supervised by an independent inspection agency, to ensure the pressure vessel meets the standards of the ASME. Upon acceptance of the test by the independent inspector, the unit is stamped with the “H” symbol for 15 psig design units and with the "S" symbol for 150 psig and greater designs. One copy of the ASME data sheets is provided to the purchaser.
8.2. Boiler Piping Hydro (Optional) As an option, Section I high pressure boiler (“S” stamped), built in accordance with the ASME Code, can be subjected to an additional hydrostatic pressure test. This test includes the integral steam and water trim piping and when included, the trim valves.
8.3. Burner & Controls To ensure proper operation of the combustion safeguard control, ignition, and main fuel light off the burner manufacturer subjects the packaged burner to a preliminary factory fire test. All burner and boiler controls are checked for circuit continuity after mounting and wiring the burner onto the boiler.
9. Nameplates & Stamping
9.1. The National Board of Pressure Vessel Inspectors registration number is stamped on the pressure vessel with the boiler serial number, year built, maximum boiler output, and minimum safety valve capacity. This information is located on the pressure vessel beneath an inspection plate, near the upper rear of the boiler. A facsimile nameplate of this data stamping is mounted near or on the front door of the boiler.
9.2. A “red-line” mark is located on each front door, indicative of the lowest permissible water level within the boiler.
9.3. Boiler Feedwater care and maintenance information is provided on a nameplate located on the boiler near the water column.
10. Guarantees
10.1. Efficiency The boiler package is guaranteed to operate at a minimum of 80% or greater, fuel input to steam pounds per hour output efficiency.
10.2. Warranty The complete package is warranted for a period of one (1) year from the date of initial start-up or 18 months from the date of shipment or notice to ship, whichever occurs first. This guarantee does not include items that are damaged due to circumstances beyond the control of Lattner Manufacturing Company Inc., carelessness, or neglect. Refer to the Lattner’s standard warranty and terms and conditions documents for more detailed information.
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Lattner Boiler Company 1411 9th St. SW Cedar Rapids, IA 52404 Telephone: (800) 345-1527 Fax: (319) 366-0770 Web: www.lattnerboiler.com
LATTNER BOILER COMPANY Page 8 Scotch Marine Boiler Operations Manual ______
Section II: Installation
WARNING: All installation procedures must be followed completely by a competent installer familiar with boilers and boiler accessories.
CAUTION: Read and follow all instructions before installing any boiler equipment. All cover plates, enclosures and guards must be maintained and in place at all times, except during maintenance and servicing.
1. Unloading The boiler was loaded by Lattner (including any accessories) and accepted by the transport company as undamaged. Before unloading the equipment, determine whether any shipping damage is apparent. Once the equipment is lifted from the trailer, any damage sustained during transit and not filed with the transport company will be the responsibility of the rigger or purchaser.
1.1. Lifting The boiler will arrive secured to a wooden skid/pallet and will include a lifting lug(s). When moving or lifting the unit, DO NOT attach sling around the boiler or to the burner in an attempt to pull the boiler.
1.2. Forklift If lifting with a forklift, extended forks should be used beneath the skid. Care must be taken to ensure that the boiler sits correctly on the forks such that the unit does not topple. Always note the weight of the boiler relative to the lifting capacity of the forklift.
1.3. Crane or Boom When lifting with a crane or boom, attach the hook to the lifting lug on top of the boiler. DO NOT attach slings or chains to any part of the boiler, boiler piping, or burner.
2. Rigging Always use a competent rigger that has experience moving and setting boilers. If the unit will be moved into the permanent location with a forklift, crane, or boom, follow the directions in Section I. However, if moving the unit through a tight space or into an area that will not permit a forklift, place the boiler on rollers or on 2” pipes and roll the boiler into place. If the unit is dragged, attach chains to the base frame only.
If the entry way is too narrow for the boiler and controls to pass through, removal of the trim and controls can be executed. One should properly denote all wiring and piping connections and match mark accordingly for attachment after the boiler is placed. It may be helpful to use a digital camera to record the location of trim items for reference.
3. Placement of Boiler
3.1. Floor Boiler must be placed on a level, non-combustible surface. NEVER install boiler on a wood floor or any other combustible surface (i.e., carpet, linoleum).
3.2. Combustible Surfaces UL specifies the following minimum clearance to combustible surfaces:
- Top 48 inches - Sides 36 inches - Flue pipe 36 inches
3.3. Non-Combustible Surfaces When placing boiler near non-combustible surfaces (i.e., cement or cinder block walls), maintain 18” around the boiler for servicing. NOTE: Any state or local fire and/or building codes requiring additional clearances take precedence over the above requirements.
4. Combustion Air
4.1. Ventilation The boiler room must be adequately ventilated to supply combustion air to the boiler. The vent must be opened to the outside to allow air to flow into the room. Proper sizing of the vent is important to ensure that sufficient free air is available for complete combustion and proper venting of the flue gases.
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Lattner Boiler Company 1411 9th St. SW Cedar Rapids, IA 52404 Telephone: (800) 345-1527 Fax: (319) 366-0770 Web: www.lattnerboiler.com
LATTNER BOILER COMPANY Page 9 Scotch Marine Boiler Operations Manual ______
4.2. Vent Size Use the following chart to determine vent size for Lattner boilers. Chart based on 1 square inch per 2,000 BTUs input.
Horsepower Required Vent Size Sq. In. Required 10 15” x 15” 209 in2 15 18” x 18” 313 in2 20 21” x 21” 418 in2 25 23” x 23” 523 in2 30 25” x 25” 627 in2 40 29” x 29” 837 in2 50 33” x 33” 1046 in2 60 36” x 36” 1260 in2 80 41” x 41” 1680 in2 100 46” x 46” 2100 in2 125 52” x 52” 2625 in2 150 56” x 56” 3150 in2 200 65” x 65” 4200 in2
4.3. Additional Ventilation The chart above shows vent sizes for one gas fired boiler. If there is other equipment in the room that uses air (large water heaters, air compressors, other boilers, exhaust fans, etc.), additional venting capacity is required.
5. Stack
5.1. Specifications Install all stacks in compliance with state and local codes. Lattner recommends double wall stack per ANSI Z2231.1, appliance category III for positive vent pressure systems for boilers operating with a maximum continuous temperature not exceeding 1000°F.
5.2. Stack Diameter
5.2.1. The entire stack must be the same size as the stack outlet on the boiler or one size larger. 5.2.2. If the boiler stack is connected to other equipment, the stack size must be increased.
5.3. Stack Connections/Sections Limit connections to one of the following combinations:
- Two 90 degree elbows - One 90 degree elbow and one tee - One 90 degree elbow and two 45 degree elbows - Four 45 degree elbows
5.4. Overall Length Avoid long runs of stack. A general rule is not to exceed 15 feet for every inch of stack diameter. For example, if the stack is 6” diameter, then the overall stack should not exceed 90 feet (6’ x 15’) in length and height combined.
5.5. Horizontal Stack Avoid any horizontal runs of stack. If unavoidable, horizontal runs should have a minimum incline of 3” per foot. If a long horizontal run (4’ or more) cannot be avoided, a draft inducer may be required to properly vent combustion gases.
5.6. Walls & Ceilings When passing through combustible walls or ceilings, a stack thimble is required. The thimble must be double wall stack, 6 inches larger in diameter than the vent stack. The material used to close the opening between the stack and the stack thimble must be non- combustible.
6. Steam Outlet
6.1. Pipe Size Size pipe according to system requirements.
6.2. Outlet Size Refer to product literature sheet for steam outlet size on a particular boiler model.
6.3. Steam Stop Valve Install a steam stop valve in the steam line as close to the boiler as is practical. Allows boiler to be isolated from the system during service work and may be helpful in throttling steam flow. Required by ASME Code if the boiler is operated over 15 psi. ______
Lattner Boiler Company 1411 9th St. SW Cedar Rapids, IA 52404 Telephone: (800) 345-1527 Fax: (319) 366-0770 Web: www.lattnerboiler.com
LATTNER BOILER COMPANY Page 10 Scotch Marine Boiler Operations Manual ______
6.4. Steam Piping Steam line should be pitched downward slightly away from the boiler and toward a steam trap. If using a steam solenoid valve, the steam line should slope upward slightly to the solenoid valve, and after the solenoid valve, the steam line should slope downward.
6.5. Codes & Standards Piping must comply with all industry standards (especially ANSI B31.1) and all state and local codes.
7. Blowdown Piping
7.1. Boiler Bottom Blowdown (See Diagram Below)
7.1.1. DO NOT REDUCE. Blowdown piping and all fittings must be the same size as the boiler blowdown connection.
7.1.2. Low pressure boilers, operating at 15 psi or less, require one blowdown or drain valve. The pressure rating of the valve must be equal to or greater than the pressure of the boiler safety valve but not lower than 30 psi.
7.1.3. Boilers operating 16 psi to 100 psi inclusive require a single blowdown form a pocket inside the valve are not acceptable blowdown valves. A Y-type or a ball valve is acceptable blowdown valves.
7.1.4. Boilers operating 101 psi to 150 psi require piping designed for a pressure of 125% of the boiler safety valve set pressure (schedule 80 blowdown piping) and two slow opening blowdown valves. If cast iron, these valves must be class 250, or if steel, these valves must be class 150, or if bronze, a WSP rating of at least 200.
7.1.5. Standard globe and gate valves that form a pocket inside the valve are not acceptable blowdown valves. Y-type and ball valves are acceptable blowdown valves.
7.1.6. All blowdown piping must meet ANSI B31.1 code and all city and state codes.
7.1.7. Galvanized piping is not acceptable for boiler blowdown piping.
7.2. Automatic Bottom Blowdown A Lattner automatic bottom blowdown valve may be used in place of one of the manual blowdown valves.
7.3. Water Level Control Drain Valve A water column type level control is supplied with one drain valve. Connect the control drain line into the bottom blowdown line after the second bottom blowdown valve.
7.4. Blowdown Discharge All boiler blowdown water must be discharged to a safe location, specifically to a blowdown separator.
7.5. Blowdown Separator Select a Lattner Blowdown Separator according to the size of the boiler blowdown connection:
1” Model 810 1-1/2” Model 1450 or 1455 2” Model 1600 2-1/2” Model 1800
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Lattner Boiler Company 1411 9th St. SW Cedar Rapids, IA 52404 Telephone: (800) 345-1527 Fax: (319) 366-0770 Web: www.lattnerboiler.com
LATTNER BOILER COMPANY Page 11 Scotch Marine Boiler Operations Manual ______
7.6. Blowdown Separator Inspection Opening The extra coupling in the separator vessel is an inspection opening. The inspection opening will be plugged.
7.7. Blowdown Separator Vent The blowdown separator must be vented to atmosphere. Vent pipe must discharge outside through the roof. DO NOT reduce the vent pipe size. NEVER connect the vent pipe from the condensate tank to the separator vent.
7.8. Blowdown Separator Drain The water leaving the separator through the drain should be piped to the sewer. Some codes require the water to pass through an air gap before entering the sewer.
7.9. Aftercooler If the water must be cooled before entering the sewer (required by some codes), then an aftercooler must be used. The aftercooler attaches to the separator drain connection and mixes cold water with the hot drain water. Units may be either manual or automatic. Select the aftercooler according to blowdown separator drain size.
205A (auto) or 205M (manual) Model 810 301A (auto) or 301M (manual) Model 1450 or 1455 525A (auto) or 525M (manual) Model 1600 625A (auto) or 625M (manual) Model 1800
7.10. Cooling Water Supply Connect cold water supply pipe to aftercooler:
205A (auto) or 205M (manual) 1/2” NPT 301A (auto) or 301M (manual) 1” NPT 525A (auto) or 525M (manual) 1-1/4” NPT 625A (auto) or 625M (manual) 1-1/4” NPT
7.11. Dead Boiler Drain Valve For draining the boiler when it is cool and not under pressure, the entire drain line must be lower than the bottom of the boiler. Pipe to sewer or floor drain. Valve must be rated up to the MAWP of the boiler.
7.12. Codes & Standards All blowdown piping, drain and sewer connections, water piping and separator connections must be done in strict compliance with all applicable codes.
8. Safety Valve
8.1. Installation Be sure safety valve is threaded securely into the boiler or into the elbow supplied with boiler. The safety valve will always be installed in the upright position.
8.2. Discharge Pipe the safety valve outlet to a safe point of discharge. DO NOT reduce the safety valve discharge piping. NEVER plug the safety valve outlet.
8.3. Supports Safety valve piping should be secured by clamps or braces to a wall or structural member. Do not allow the discharge piping to hang on the safety valve.
8.4. Codes & Standards All safety valve piping and supports must conform to all applicable codes.
9. Gas/Fuel Train Piping
9.1. Components Generally, a gas train should include the following:
- Manual gas cock - Main gas pressure regulator - Main gas valve - Pilot gas pressure regulator - Pilot gas valve - Flame failure control
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9.2. Motorized Gas Valve The main gas valve and pressure regulator are two separate components. The motorized gas valve is a two-piece valve. The lower section is the valve body, which is a plunger valve. The upper section is the actuator. The actuator has a small built-in hydraulic system. The hydraulic system opens and closes the valve. The motorized gas valve is a gas valve only, and has no other functions. This gas train requires a separate main gas pressure regulator, pilot gas pressure regulator and pilot valve.
As an option, the combination gas valve can be supplied with an intermittent pilot. This system has a spark-ignited pilot and will shut off the gas within four seconds of a flame failure.
9.3. Gas Supply Pipe The gas pipe to the boiler must be at least the same size as the gas train supplied with the boiler. DO NOT reduce.
9.4. Drip Leg Gas supply piping must be installed with a proper drip leg ahead of any gas train components.
9.5. Gas Supply Pressure
Natural Gas: Supply pressure should be between 6” and 11” water column ahead of the gas pressure regulator when the boiler is running. Manifold pressure when the boiler is operating should be 4-1/4” to 4-1/2” water column.
Liquid Propane (LP): Gas supply pressure should be 11” water column. A pressure regulator will not be supplied with a propane fired boiler.
WARNING: NEVER use Teflon tape on any part of the gas train piping. This will void any warranty on the gas train assembly.
9.6. Codes & Standards All gas piping must be done in accordance with all applicable codes (National Fuel Gas Code, utility company requirements, local building codes etc.).
10. Boiler Feed Systems
10.1. Condensate Return Systems
10.1.1. Make-Up Water Supply Connect city water line to the float valve with the boiler feed system. Install a manual shut-off valve in the water line.
10 HP through 50 HP 1/2” NPT 60 HP through 200 HP 3/4” NPT
10.1.2. Pump Suction Line This is pre-piped from the factory with an isolation valve and strainer.
10.1.3. Pump Discharge Line DO NOT reduce. Use 1” NPT pipe and fittings between pump and boiler. Install two spring-loaded check valves. Install a hand shut-off valve between the last check valve and the boiler. Keep the number of elbows and fittings to a minimum.
10.1.4. Condensate Return Line Condensate from all steam traps should be tied into a common return line. The condensate return line should be pitched downward toward the condensate return tank.
10.1.5. Condensate Return System Vent Condensate return tank must be properly vented to atmosphere. Vent should discharge through the roof or through a wall to the outside. Do not reduce the vent pipe size.
10 HP through 50 HP 1” NPT 60 HP through 200 HP 1-1/2” NPT
10.1.6. Condensate Return System Overflow Pipe to floor drain. Overflow connection should be at least as large as the condensate return.
10.1.7. Condensate Return System Drain Connection Pipe to floor drain. Install a valve in the line. 1” NPT line is sufficient.
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10.2. Solenoid Water Valve
10.2.1. Water Pressure This system will work only if the water supply pressure is at least 10 psi higher than the boiler pressure.
10.2.2. Water Inlet Refer to the boiler assembly print for correct connection and location of the feedwater inlet.
10.2.3. Piping The solenoid water valve assembly will be piped in the following order: Y-type strainer, solenoid valve, spring-loaded check valve, globe valve, and boiler. All pipe is 1/2” NPT.
10.2.4. Water Supply Connect water supply to the strainer.
11. Electrical Connections
11.1. Reconnecting Controls If the boiler was shipped with controls removed, re-connect the wires according to the wiring diagram. All wires that need to be reconnected will have a tag indicating the control or terminals to which they must be connected.
11.2. Electrical Supply Supply 120 volt single phase from a separate fused disconnect. Use a 30 amp circuit breaker or fused disconnect if the boiler has a 3/4 hp pump motor or larger. Refer to wiring diagram for specific instructions.
11.3. Wiring Water Feed System Wire the solenoid water valve, boiler feed pump or pump motor starter as indicated on the wiring diagram.
11.4. Power Supply Connect the power supply to the terminals in the panel box as shown on the wiring diagram. "Hot" side will be marked L1. Neutral will be marked L2.
11.5. Secure Connections After all wiring is complete and before any power is supplied to the boiler, be sure all wiring connections are tight.
11.6. Turn Pump Switch “ON” Turn on the pump switch. Pump or solenoid valve should start immediately. If not, see troubleshooting section.
11.7. Check for Leaks While the boiler is filling, check for leaks in the piping and around boiler. If there are leaks, turn off the pump switch and fix all leaks before continuing.
12. Before Firing the Boiler
12.1. Spare Fittings Check that all unused pipe nipples are plugged or capped.
12.2. Float Block Remove the float block screwed into the body of the McDonnell Miller level control. Replace with a malleable iron plug.
12.3. Condensate Return System Make sure there is make-up water supply to the tank. Make sure there is water in the tank.
12.4. Turn Pump Switch “ON” Turn on the pump switch. Pump should start immediately. If not, see the troubleshooting section of this manual.
12.5. Check for Leaks While the boiler is filling, check for leaks in the piping and around the boiler. If there are leaks, turn off the pump switch and fix all leaks before continuing.
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13. Pressuretrols: Controller and Limit
13.1. Standard All Lattner boilers will have at least two pressure switches, a “controller” and a “limit”.
13.2. Controller Before the boiler is started, the steam pressure is 0 psi. At this point, the controller is in the "on" condition and is calling for heat. When the boiler switch is turned on, the boiler will fire and start generating steam. As the boiler fires, the steam pressure will rise. When the steam pressure reaches the controller's set point, the controller will shut off the burner. As steam is used, the pressure will begin to drop. When steam pressure drops enough, the controller will start the burner again. The controller will continue to operate in this manner to maintain boiler pressure.
13.3. Setting Controller On the left side of the pressuretrol is the set point indicating scale labeled "MAIN". Turn the main scale adjustment screw until the set point indicator aligns with the desired operating pressure. Turn screw clockwise to increase pressure, counterclockwise to decrease pressure.
13.4. Differential When the boiler pressure reaches the set point the controller shuts off the burner. The pressure must drop by a set amount before the controller will turn on the burner again. That amount is called the differential. The differential is adjustable.
13.5. Setting the Differential On the far left side of the pressuretrols is the differential indicating scale labeled "DIFF". Turn the differential adjusting screw until the indicator aligns with the desired differential. A minimum differential will maintain the boiler pressure closer to the set point. A larger differential will help prevent rapid on and off cycling of the boiler.
13.6. Limit The limit switch is similar in operation to the controller but has a slightly higher set point. If the controller fails to shut off the boiler and the steam pressure continues to rise, the limit switch will shut down the boiler. The controller is an operating switch; the limit serves as an auxiliary safety cut-off. The limit switch is supplied with a manual reset function. If the steam pressure trips the high limit switch, the limit locks in the off position. The limit switch will not reset until the manual reset lever is pressed.
13.7. Setting the Limit This is done using the same procedure as for the controller. The limit setting will be slightly higher than the controller's set point. For low pressure boilers (15 psi or less), set the limit switch 4 psi higher than the controller and 3 psi lower than the safety valve setting. For high pressure boilers, set the limit switch at least 10 psi higher than the controller and 5 psi lower than the safety valve setting.
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13.8. Night Operating Pressure Switch A third pressure switch may be supplied as an option. This switch allows the boiler to operate at low pressure at night for heating the building. Set the night operating pressure switch at approximately 10 psi. The boiler panel box will also be wired with a High/Low selector switch. Setting the selector switch at “Low”, the boiler will operate at 10 psi. When the switch is turned to “High”, the night operating switch is by-passed and the boiler operates at the normal operating pressure.
13.9. Example Boiler with a 100 psi safety valve. Set the controller at 80 psi with an 8-10 psi differential. Set the limit switch at 90 psi. Turn on the boiler, burner will fire. When the steam pressure reaches 80 psi, the controller shuts down the burner. When the pressure drops to 70- 72 psi the burner restarts. The boiler continues to cycle to maintain 80 psi. If the steam pressure rises to 90 psi, the limit switch shuts off the boiler. The manual reset on the limit switch must then be reset before the boiler will operate again.
For any additional information on the Honeywell Pressuretrols, refer to the Honeywell product sheet in the back of this manual.
14. Firing the Boiler
14.1. Leave the Boiler Switch “OFF” 14.2. Purge the Gas Line 14.3. Gas Supply 14.4. Turn the Boiler Switch “ON” 14.5. The Burner should Fire
If burner fails to fire, refer to troubleshooting section of this manual (Section IV).
14.6. Burner Head Pressure Check gas pressure at burner head. Burner head pressure should be as specified in the burner manual.
14.7. Adjust Pressure If the burner head pressure is not within the range specified, adjust gas pressure regulator. Motorized gas trains have separate gas pressure regulators. Removed large slotted cover screw and turn adjusting screw underneath. Refer to Maxitrol manual.
14.8. Check for Gas Leaks Brush a soapy water solution on each connection in the main gas and pilot gas lines. Look for bubbles. If there are any gas leaks, shut off the main gas supply and fix any leaks before continuing. Repeat steps 1 through 6.
14.9. Adjust the Burners Forced draft burners can only be properly set up by using combustion test equipment. These burners cannot be set up solely on the appearance of the flame. Refer to the burner manual in the product literature section for proper carbon monoxide, carbon dioxide, and excess oxygen levels.
14.10. Burner Tuning Objectives The following measures are approximations only. Data may vary by location, environment, fuel, gas pressure, BTU content and more. Refer to burner manual for more specific instructions, including low-NOx burner instructions for California and Texas.
Constituent Value Gas Supply Pressure 6” w.c. (minimum) Manifold Pressure 4-1/4” w.c. (minimum)
O2 4.5% to 7.5% CO2 8% to 10% CO Less than 100 ppm
NOx Less than 60 ppm Stack Temperature 425°F to 500°F Efficiency 80% to 83%
14.11. Pressuretrols Allow the boiler to reach its operating pressure. Check the pressuretrols to be certain they’re are set as described and functioning properly.
14.12. Level Controls Make certain the level control feeds water into the boiler and maintains a proper water level.
14.13. Odors It is normal for a new boiler to give an odor when it first fires. This odor will generally subside within two days.
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15. Boil Out recommendations for New Boilers With proper operation and maintenance you can expect years of trouble free service from your new Lattner boiler. The procedure for correct operation and care of your unit is not complicated, nor is it time consuming. It is necessary to clean the inside of the new boiler of oil and grease used as tube rolling lubricants, threading, and/or other various reasons beyond the manufacturer’s control. Since these coatings may lower the heat transfer rate of the heating surfaces, failure to remove these coatings will result in your unit foaming, priming, carry-over or other damage. The boil out operation is easily accomplished by following the procedure as outlined below:
15.1. Fill the boiler to the normal water line. Close boiler steam stop valve in the steam line.
15.2. Remove safety valves at the top of the boiler. The safety valves must be removed to prevent any contaminants or boil out solution from entering them.
15.3. Tri-sodium phosphate and caustic soda each in the amount of one pound per 50 gallons of water are the suggested chemicals for cleaning boilers. Dissolve these compounds in water and add dissolved chemicals through an opening at the top of the boiler. NOTE: When dissolving and mixing the boil-out chemicals, the use of a suitable face mask, goggles, rubber gloves, and protective clothing is mandatory. DO NOT permit the dry chemicals or the concentrated solution to come in contact with skin or clothing.
15.4. It is necessary to connect an overflow pipe from the safety valve opening in the boiler to a safe point of discharge. After adding the boil out solution, add water to the boiler until it is completely filled.
15.5. Fire the boiler intermittently at low fire for 4 to 5 hours. Maintain just enough heat to hold the solution at the boiling point. IT IS CRITICAL THAT YOU DO NOT OVER FIRE BOILER DURING THIS PORTION OF THE START UP. Do not allow boiler to produce any steam pressure. During this procedure, allow just a small amount of water to enter the boiler to carry off any surface impurities through the overflow pipe. Continue the process until the overflow water appears clear.
15.6. Stop the burner and allow the water to cool to about 120°F. Drain the boiler while the water is still warm. NOTE: Prior to draining the boiler, check with local water treatment facilities to determine whether special instructions or permits are required to dispose of the water.
15.7. Remove the handhole (and manhole) plates from the boiler and wash the interior with tap water at full pressure through a nozzle. Wash until all evidence of dirt, mud, and impurities are removed through the bottom handhole openings. Inspect the internal surfaces. If not clean, repeat the boil out procedure.
15.8. After closing the openings and reinstalling the safety valves, fill the boiler to its normal water level and fire it until the water temperature is at least 180°F to drive off any dissolves gasses and oxygen which might otherwise corrode the metal.
On a steam system, the condensate should be wasted until test show the elimination of undesirable impurities. During the period the condensate is wasted, attention must be given to the treatment of the raw water used as make up so that an accumulation of unwanted materials or corrosion does not occur. Follow the advice of you water treating company.
On a hot water system, chemical cleaning of the entire system is generally necessary and the entire system should be drained after treatment. Consult a water treatment company for recommendations, cleaning compounds, and applicable procedures.
16. Standard Maintenance Items
16.1. General There are three standard maintenance items which should be kept in stock at all times to unnecessary shut down, handhole gaskets, McDonnell Miller head gaskets, and sight glasses.
16.1.1. Gaskets The handhole gaskets and the McDonnell Miller head gasket must be replaced after each internal inspection. If any leaks are present around the gasket surfaces, replace the gasket immediately. High pressure water and steam leaks will erode the metal surfaces and cause expensive repairs. Keep a full set of handhole and McDonnell Miller head gaskets in stock at all times.
16.1.2. Sight Glasses A sight glass with gaskets and washers should be in stock. Replace the sight glass with new gaskets and washers.
16.2. Routine Service These standard maintenance items are considered routine repair parts and are not covered under warranty.
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17. Water Quality Limits for Lattner Steam Boilers
Constituent Recommended Value or Limit Oxygen 0 parts per million Carbon Dioxide 0 parts per million pH 9.0 to 10.0
Total Hardness 1 parts per million as CaCO3 Total Alkalinity 600 parts per million as CaCO3 Total Dissolved Solids 2200 to 2500 parts per million Total Iron <0.1 parts per million Specific Conductance 3500 umho/cm non-neutralized Silica <150 parts per million Oily Matter <0.1 parts per million
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WARRANTY VALIDATION & BOILER START UP REPORT
The following information must be recorded during each boiler start up. This information must be returned to Lattner Boiler Manufacturing Company for warranty validation. If this information is not returned, warranty consideration may not be extended.
Lattner Boiler Model: ______Owner Name: ______National Board Number (“NB”): ______Company Name: ______Lattner Dealer Name: ______Street Address (start up location): ______Start Up Company: ______State: ______Start Up Date: ______Zip Code: ______Start Up Technician: ______Telephone Number: ______
Natural Gas or LP (Propane) Gas Voltage: _____ v / _____ ph / _____ hz Gas Pressure at Train Inlet: _____” w.c. (boiler OFF) Pilot Signal Reading: _____ VDC
Gas Pressure at Train Inlet: _____” w.c. (boiler ON) O2: _____%
Manifold Pressure: _____” w.c. (boiler OFF) CO2: _____% Manifold Pressure: _____” w.c. (boiler ON) CO: _____ parts per million (ppm)
Gas Pressure at Pilot Tee: _____” w.c. (boiler OFF) NOx: _____ parts per million (ppm) Gas Pressure at Pilot Tee: _____” w.c. (boiler ON) Stack Temperature: _____ degrees Fahrenheit Input: _____ btu/hr (clocked at meter) Combustion Efficiency: _____%
Limit Control Setting (cut out): _____ psi or °F Modulating Control Setting: _____ psi or °F Operating Control Setting: _____ psi or °F Modulating Control Differential Setting: ____ psi or °F Operating Control Differential Setting: _____ psi or °F
Checked for proper operation of:
Low Water Cut Off yes no Barometric Damper yes no High Water Cut Off yes no Boiler Combustion Air yes no Flame Safeguard Control Ignition yes no Boiler Flue/Stack Compliance yes no Flame Safeguard Main Flame yes no Gas Line Leakage yes no Air Flow Switch yes no Gas Equipment Ventilation yes no
Notes:
IMPORTANT: For warranty validation, return this document to (mail, fax, or email):
Lattner Boiler Manufacturing Company P.O. Box 1527 Cedar Rapids, IA 52406 T: (319) 366-0778 F: (319) 366-0770 E: [email protected] LATTNER BOILER COMPANY Page 18 Scotch Marine Boiler Operations Manual ______
Section III: Boiler Care & Maintenance
WARNING: All maintenance procedures must be performed by competent personnel familiar with boilers and boiler accessories.
CAUTION: Read and follow all instructions before working on any boiler equipment.
NOTE: Certain maintenance items concerning specific components may be found in the product literature specifications of this manual.
1. Daily Procedures
1.1. Blowdown primary low water cut-off while burner is firing. 1.2. Verify that feedwater pump cycles normally and that burner shut off. 1.3. Observe the burner starting sequence and flame characteristics to verify normal behavior. 1.4. Conduct visual check of all pressure and temperature gauge readings. 1.5. Check safety valve, handholes, and manway for signs of leakage.
2. Weekly Procedures
2.1. Check function of auxiliary low water cut-off while burner is firing. Verify proper response of alarms. 2.2. Check flame safety control’s response to lack of flame with main gas OFF. Start burner with pilot OFF, verify lock-out. 2.3. During and after flame failure test, observe ignition spark and pilot flame for abnormalities. 2.4. Record pilot and main flame signals if digital display module is available. 2.5. If boiler is equipped with modulating burner, verify that adequate differential exists between operating and modulating controls to prevent short cycling. 2.6. Verify that main fuel valves are closing within specified times. Check valve position indicators.
3. Monthly Procedures
3.1. Check air flow switches mechanically and electrically. Snap switches can stick in closed position if shaft is dirty. Disconnect wire, start burner, verify that pilot does not light.
3.2. Check low fire start proving switch circuit with voltmeter. Terminal must not be powered until motor returns to low fire position. If wire is disconnected, verify that pilot does not light.
3.3. Check open damper proving switch circuit with voltmeter. Terminal must not be powered until motor reaches high fire position. If wire is disconnected, verify that motor remains at high fire position.
3.4. Test main gas valves for leakage. Close checking cock, connect hoses to open lead test valves, submerge hose ends in water, and watch for bubbling.
3.5. Test fuel pressure interlock switches. With burner in normal operation (preferably at high fire), raise low gas or oil pressure switch setpoint above available fuel pressure. Burner must shut off when visual indicator trips. Test high gas pressure switch by reducing setpoint below existing manifold pressure. Again, burner must shut off when indicator trips.
3.6. After returning to normal setpoints, burner must no restart until switches have been manually rest.
3.7. Test oil atomizing medium interlock by interrupting flow of compressed air or steam to burner. Oil valves must close, with subsequent flame safeguard lock-out.
3.8. Manually lift safety valve set with test level while boiler is at normal operation pressure.
3.9. Check flame safety control’s response to lack of flame with main gas OFF. Start burner with pilot OFF, verify lock-out.
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4. Annual Procedures
4.1. Since the low water cut-off wiring terminal strips tend to be at the highest operating temperatures found in the boiler control circuit, check wire insulation for brittleness, cracking, or missing patches.
4.2. Clean all safety control related piping, including low water cut-off equalizers, pressure control manifolds, and air flow switch tubes.
4.3. Check boiler pressure gauge against calibrated master gauge or with dead weight tester. New gauges are built to 1% accuracy.
4.4. Jumper operation control and run boiler under manual control at reduced load to determine proper operation of limit.
4.5. Bypass both operating and high limit controls under manually controlled low load condition. Gradually bring boiler pressure up to safety valve setpoint. 15 psi valves must open at 15 psi. Valves rated 15 psi to 69 psi are permitted 2 psi tolerance, and 70 psi to 300 psi valve vary 3%.
4.6. Remove gas line strainer basket and clean.
5. Care of Idle Boilers Boilers used on a seasonal basis that will be idle for a long period of time (in excess of 30 days) should be laid up either under a dry or wet method during periods of inactivity.
5.1. Boilers Laid Up Dry In the event that the boiler could be subject to freezing temperatures or if the boiler is to be idle for an excessive period of time, the following preparation should be made and carried out so that the boiler is not damaged over its period of inactivity:
5.1.1. Drain and clean the boiler thoroughly (both fire and water sides) and dry the boiler out.
5.1.2. Place lime or another water absorbing substance in open trays inside the boiler and close the unit tight to exclude all moisture and air.
5.1.3. All allied equipment such as condensate tanks, pumps, etc., should be thoroughly drained.
5.2. Boilers Laid Up Wet In order to protect the boiler during the short periods of idleness, the boiler be laid up wet in the following manner:
5.2.1. Fill the boiler to overflowing with hot water. The water should be approximately 120°F to help drive out the free oxygen. Add enough caustic soda to the hot eater to maintain approximately 350 parts per million of alkalinity and also add enough sodium sulphide to produce a residue of 50 to 60 parts per million of this chemical.
5.2.2. Check all boiler connections for leaks and take a weekly water sample to make sure that the alkalinity and sulphide are stable.
When cleaning a boiler in preparation to laying up the boiler, the water side of the unit should be cleaned and then the unit fired to drive off gases. The fire side should then be cleaned. An oil coating of fire side metal surfaces is beneficial when the boiler is not used for extended periods of time. This will prevent oxidization of the metal. Fuel oil lines should be drained and flushed of residual oil and refilled with distillate fuel. If oil boilers are to be laid up, care of oil tanks, lines, pumps and heaters is similarly required.
6. Care & Service of Boiler Tubes
6.1. Hard water causes short tube life in scotch marine boilers. Chemical action from hard water plus oxygen in the water will attack the boiler tubes. This action can be so drastic that tubes may be pitted through in a few months.
6.2. Water that is too soft (zero soft) causes pitting of tubes and boiler plates below the water line. Ideal feedwater is 3 to 6 grains in hardness. Water that is too soft is usually apparent because it causes a bouncing water level in the gauge glass and usually causes foaming and priming, throwing water into the main steam piping.
6.3. When first installed, new boiler may develop leaks around the tube ends. While the boiler was tight and showed no leaks during final hydrostatic testing by the ASME inspector (third party), leaks often develop after the boiler has been shipped some distance. If leaks do not take up and stop after the boiler has been operated for 24 hours, tubes that are leaking must be slight re-rolled.
6.4. Re-rolling of the tubes to sop leaks, when the boiler is new or if it has been in service for some time, is a very delicate procedure. There is danger of over-rolling. When the tubes are installed in a new boiler, they are rolled just enough to prevent leakage. Re-rolling must be done on the same basis. The boiler should be subjected to a small amount of water pressure when tubes are being re-rolled. The tube roller can then be used sparingly and just enough to stop the leaks. Even one turn of the tube roller may be too much. Over- rolling makes the tubes so thin that during expansion and contraction boiler pressure will bend the thin part of the tube inward. The tube will then leak constantly, making it necessary to replace the tube. ______
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6.5. If tubes leak at rolled joints after boiler had been in service for some time, the cause of such leaks is usually one of the following:
6.5.1. Firing the boiler when it is low water.
6.5.2. Lime and scale deposits around the tubes near the rolled joints. This insulates the joint from the water and permits overheating of the tube ends, causing leakage.
6.5.3. Feeding water to the boiler at any point near tube sheets may cause the boiler leak. Instruction sheets show the proper feedwater inlet. Scotch marine boilers have water inlets halfway up the side of the boiler shell.
6.5.4. Boiler can be chilled causing leaks by blowing the boiler completely down when it is too hot. Boiler pressure should not exceed 15 psi for complete blowdown.
6.5.5. Boiler can be chilled causing leaks by filling with cold water too soon after blowdown. After complete blowdown and before filling with water, the boiler should be allowed to cool for two hours if there is no internal firebrick and three hours if there is an internal firebrick-lined combustion chamber.
7. Boiler Tube Replacement
7.1. Prior to tube replacement, it is necessary to have these tools available:
7.1.1. Tube driving mandrel and sledge hammer, or cutting torch 7.1.2. Chisel 7.1.3. Tube roller, properly sized for boiler tube diameter and thickness 7.1.4. Flaring tool 7.1.5. Beading tool 7.1.6. Socket wrench 7.1.7. Oil
7.2. In addition to these basic tubes, tube replacement is simplified with the following equipment:
7.2.1. Air compressor or air source 7.2.2. Small air hammer 7.2.3. Impact wrench or tube rolling motor
7.3. Boiler Tube Removal, Method A
7.3.1. In most cases the boiler tube will be covered with scale, therefore it is extremely difficult to pull the tube out of the tube sheet. Equipment is available that can easily remove scale encrusted tubes through their respective tube holes; however these tools are very costly.
7.3.2. Using a chisel, carefully remove the bead from one end of the tube to be replaced. IMPORTANT: Extreme care must be exercised when using the chisel so the tube sheet and the tube hole are not damaged.
7.3.3. A special driving mandrel must be placed into the tube end from which the bead has been removed. The mandrel must fit inside the end of the tube and its shoulder must be able to pass through the tube hole in the tube sheet. Preferably the mandrel should be attached to the end of a steel rod about 2' or 3’ in length. After inserting the mandrel with its rod into the tube, a sledge hammer can be used to drive the tube out of the tube sheet. After the tube extends about 2’ from the opposite tube sheet, it can generally be manipulated to crush the adhering scale as it is physically removed. As mentioned above, tube removal by this method is very difficult.
7.4. Boiler Tube Removal, Method B
7.4.1. IMPORTANT: This method of tube removal with a cutting torch can be used ONLY if the tube to be removed can be withdrawn from a handhole opening. It is not possible to remove a tube severed with a cutting torch from a tube hole.
7.4.2. In this method the tube is severed with a cutting torch and is removed through a handhole opening.
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8. Handhole Plate Removal & Installation
8.1. Disconnect all power to the boiler. The boiler must be cool and drained of all water.
8.2. Remove the handhole plate nut. Remove arch over handhole plate. Remove handhole plate. Sometimes it is necessary to tap on the handhole plate to loosen it. Make sure the handhole plate does not fall inside the boiler.
8.3. Scrape the inside of the boiler around the handhole area to remove any scale or old gasket material. Scrape the old gasket material off the handhole plate. Make sure there are no burrs around the handhole opening. Remove any burrs with a file.
8.4. Place the handhole plate back into the boiler handhole plate opening without the gasket. If the plate rocks back and forth, remove the high spots on the handhole plate with a file. DO NOT LEAVE THE HANDHOLE PLATE INSTALLED IN THE BOILER WITHOUT THE GASKET.
8.5. Install the gasket on the handhole plate. Make sure the gasket is pressed firmly down on to the handhole plate. DO NOT USE ANY GREASE. LUBRICANTS OR ADHESIVES WHEN INSTALLING HANDHOLE GASKETS.
8.6. Reinstall the handhole plate into the boiler. Replace the arch over the stud of the handhole plate. The arch should extend across the width (short way) of the handhole opening.
8.7. Replace the nut on the handhole plate stud. Tighten the nut hand tight, then turn the nut ¼ turn with a socket. DO NOT COMPRESS THE GASKET EXCESSIVELY. This will only shorten the life of the gasket.
8.8. Reconnect the power to the boiler.
8.9. Check the handhole plate for leakage with pressure on the boiler. If leaks are noted, remove the pressure from the boiler, let the boiler cool and drain to reposition the handhole plate. Repeat steps 12 through 16.
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Lattner Boiler Company 1411 9th St. SW Cedar Rapids, IA 52404 Telephone: (800) 345-1527 Fax: (319) 366-0770 Web: www.lattnerboiler.com
LATTNER BOILER COMPANY Page 22 Scotch Marine Boiler Operations Manual ______
9. Sight Glass Removal & Installation
9.1. Boiler and pump should be switched off. Boiler should be cool and the water level should be below the lower water gauge fixture. Close the upper and lower water gauge valves.
9.2. Loosen both sight glass packing nuts (top and bottom) with a wrench. Slide glass carefully upward into the upper fixture. Glass should lift out of the lower fixture.
9.3. Pull glass down, out of the upper fixture tilting the glass slightly to clear the lower fixture. Be careful not to break the sight glass when removing. Assemble the new sight glass as shown. ALWAYS replace the gaskets and brass washers when installing a new sight glass.
9.4. Slide the new glass into the upper fixture. Glass should clear the lower fixture and tilt into position. Slide the sight glass down into the lower fixture. Equalize the gap between the upper and lower fixtures.
9.5. Tighten the sight glass packing nuts hand tight. Use a wrench to tighten 1/4 turn past hand tight. NEVER over tighten the sight glass. This will crack the glass and cause it to shatter under pressure.
9.6. Open the upper and lower gauge valves. Switch on boiler and pump.
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Lattner Boiler Company 1411 9th St. SW Cedar Rapids, IA 52404 Telephone: (800) 345-1527 Fax: (319) 366-0770 Web: www.lattnerboiler.com
LATTNER BOILER COMPANY Page 23 Scotch Marine Boiler Operations Manual ______
10. McDonnell Miller Servicing
10.1. Disconnect all power to the boiler. The boiler should be cool and drained of all water just below the McDonnell Miller control. Make sure all water is drained from the McDonnell Miller control by opening the control blowdown valve.
10.2. Disconnect the wiring and conduit connection to the McDonnell Miller. Tag all wires to ensure they are reconnected properly.
10.3. Remove the eight bolts holding the operating mechanism to the McDonnell Miller body. Use a 9/16" wrench or a crescent wrench. It may be necessary to tap near the base of the operating mechanism to free it from the body.
10.4. Lift the McDonnell Miller operating mechanism out of the body. Be careful to avoid damaging the float and float arm which extend into the body of the McDonnell Miller.
10.5. Carefully scrape the old gasket from the body and the operating mechanism of the McDonnell Miller. Remove any scale in the McDonnell Miller body. Always check the operating mechanism for any scale that might be blocking the float or float arm.
10.6. Check the float for any holes. Hold the float submerged in a bucket of water and look for any air bubbles coming from the float. Always reassemble the McDonnell Miller operating mechanism to the body with a new gasket.
10.7. Reinstall the eight bolts to the operating mechanism. Draw up the bolts evenly to prevent damage to the gasket, body or operating mechanism. Do not over tighten the bolts.
10.8. Reconnect the McDonnell Miller per wiring diagram. Reconnect all power to the boiler.
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Lattner Boiler Company 1411 9th St. SW Cedar Rapids, IA 52404 Telephone: (800) 345-1527 Fax: (319) 366-0770 Web: www.lattnerboiler.com
LATTNER BOILER COMPANY Page 24 Scotch Marine Boiler Operations Manual ______
11. Warrick Relay Replacement
11.1. Disconnect all power to the boiler.
11.2. Pull relay out by hand. This may take a little force but be careful. Replace the Warrick with a new 26M series Warrick. The relay has a small tab so that it can be installed only one way.
11.3. Reconnect the power to the boiler.
12. Auxiliary Low Water Cut-Off Probe Cleaning
12.1.1. Disconnect all power to the boiler.
12.1.2. Remove the four screws on top of the probe enclosure with a Phillips screwdriver. Remove the wire from the probe using a 5/16" wrench or a crescent wrench. Only the wire on the probe is to be removed.
12.1.3. Use a 13/16" spark plug socket and remove the probe. Clean the stainless steel probe and probe fitting. Reinsert the probe using a 13/16" spark plug socket. Only tighten the probe enough to stop any steam leaks. Over-tightening will destroy the threads of the enclosure.
12.1.4. Reinstall the probe wire to the probe. Reassemble the cover to the enclosure with the four Phillips screws. Reconnect power to the boiler.
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Lattner Boiler Company 1411 9th St. SW Cedar Rapids, IA 52404 Telephone: (800) 345-1527 Fax: (319) 366-0770 Web: www.lattnerboiler.com
LATTNER BOILER COMPANY Page 25 Scotch Marine Boiler Operations Manual ______
Section IV: Troubleshooting
WARNING: All troubleshooting procedures must be followed completely by competent personnel familiar with scotch marine boilers and accessories.
CAUTION: Read and follow all instructions before troubleshooting any boiler equipment.
1. Normal Operation All Lattner forced draft gas-fired boilers follow the same operating sequence:
1.1. Turn the pump switch on. 1.2. McDonnell Miller pump control turns on the pump or solenoid water valve. 1.3. Pump or solenoid valve fills boiler. 1.4. McDonnell Miller shuts off the pump or solenoid water valve when water is at normal operating level. 1.5. Turn boiler switch to the on position. 1.6. Gas valve opens and main burners light. 1.7. Boiler pressure will rise to the pressure controller’s set point. The then controller will shut off the gas valve. 1.8. When the boiler calls for water, the McDonnell Miller level control will turn on the pump or solenoid water valve. 1.9. If the pump cannot fill the boiler, the McDonnell Miller low water cut-off will shut down the boiler. 1.10. If the McDonnell Miller does not shut down the boiler, the auxiliary low water cut-off will shut down the boiler. 1.11. If the boiler has optional controls, refer to the wiring diagram.
2. Basic Service Tools The following basic equipment will aid in troubleshooting Lattner boilers:
2.1. Schematic diagram of the boiler 2.2. Volt/ohm meter 2.3. Gas pressure gauge(s) 2.4. Combustion Analyzer
3. Before You Begin Before you begin any troubleshooting procedures, check the following:
3.1. Make sure the pilot is lit. 3.2. Be certain boiler switch is on and that there are 115 volts supplied to the boiler control circuit. 3.3. Be certain pump switch is on and check for proper pump voltage and phase if different from boiler circuit. 3.4. Check if breaker is tripped or if fuse is blown. 3.5. Make sure there is water in the boiler. 3.6. Be certain manual gas cock is open and that gas is supplied to the boiler. 3.7. Be certain that all manual resets, if supplied with the boiler, are reset.
Note: Generally, all Lattner boiler controls are wired in series. The boiler operating controls and limits form a series circuit. When all switches close, the boiler should fire.
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Lattner Boiler Company 1411 9th St. SW Cedar Rapids, IA 52404 Telephone: (800) 345-1527 Fax: (319) 366-0770 Web: www.lattnerboiler.com
LATTNER BOILER COMPANY Page 26 Scotch Marine Boiler Operations Manual ______
4. Troubleshooting The chart below is a general chart that shows common problems that may occur in boiler operation. This chart is only to be used by competent service personnel familiar with Lattner boiler equipment and controls. To us this chart, read down the side of the chart from the problem, then read the right side for possible causes. The causes are arranged with the most common first. If the problem is not on the chart below, consult a trained boiler service company.
Problem Cause
Boiler and pump switches are ON, 1. Circuit breaker tripped or fuse blown. pump does not run, low water level in 2. McDonnell Miller piping is plugged. boiler. 3. McDonnell Miller float is stuck. 4. McDonnell Miller is wired incorrectly. 5. Pump or solenoid water valve is wired incorrectly.
Pump runs but does not maintain water 1. Hand valve between pump and boiler is closed. level in boiler. 2. Bad check valve. Always replace with a spring-loaded check valve. 3. Bad steam traps. 4. Water temperature is too hot. 5. Strainer is plugged. 6. Pump isolation valve is closed. 7. No water is supplied to the pump. 8. Pump out of adjustment.
Pump or solenoid overfills the boiler. 1. Solenoid water valve is not seating properly. 2. McDonnell Miller float is operating incorrectly. 3. McDonnell Miller mercury tube is malfunctioning. 4. McDonnell Miller is wired incorrectly. 5. Pump is wired incorrectly.
Boiler takes excessive time to reach 1. Burners out of adjustment. pressure. 2. Improper gas pressure. 3. Insufficient quantity of gas supplied to the boiler. 4. Boiler flue passages need to be cleaned. 5. Gas valves firing on low fire only. 6. Scale build-up inside boiler.
Limit switch always shuts down boiler. 1. Scale build-up inside of the boiler. 2. Operating pressure switch is set higher than limit switch. 3. Operating pressure switch is not operating properly.
Boiler shuts down with auxiliary low 1. Pump switch is turned off. water cut-off. 2. Probe wired incorrectly. 3. Auxiliary level control relay wired incorrectly. 4. Probe has scale, dirt, or debris on it. 5. Foaming problem in boiler. 6. Water in boiler is too soft. 7. McDonnell Miller is not operating correctly. 8. Pump is not functioning properly. 9. Bad check valve. Always replace with spring-loaded check valve. 10. No water supplied to the pump. 11. Probe is out of probe socket.
Flashback or rough light-off of main 1. Air shutters/louvers on the burner are open too wide. burners. 2. Pressure switch differential set to close. 3. Drafty conditions around the boiler. 4. Lack of free air in the boiler room. 5. Pilot burner not functioning properly. 6. Incoming gas line to gas valve is too small. 7. Pressure regulator not functioning properly. ______
Lattner Boiler Company 1411 9th St. SW Cedar Rapids, IA 52404 Telephone: (800) 345-1527 Fax: (319) 366-0770 Web: www.lattnerboiler.com
LATTNER BOILER COMPANY Page 27 Scotch Marine Boiler Operations Manual ______
8. Gas valve not functioning properly. 9. Pilot burner is not in correct location. 10. Pilot tubing is blocked or kinked. 11. Blocked orifices on main or pilot burner.
Pilot fails to light or stay lit. 1. Pilot gas pressure too high or too low. 2. Main or pilot gas line not purged. 3. Excessive draft around the boiler. 4. Pilot tubing blocked or kinked. 5. Pilot gas valve not functioning properly. 6. Pilot safety switch.
Safety valve(s) fail. 1. Pressure in boiler exceeds pressure setting of safety valve. 2. Operating and/or limit switch set higher than safety valve. 3. Scale build-up inside boiler. 4. Gas valve wired incorrectly. 5. Operating and/or limit switch wired incorrectly.
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Lattner Boiler Company 1411 9th St. SW Cedar Rapids, IA 52404 Telephone: (800) 345-1527 Fax: (319) 366-0770 Web: www.lattnerboiler.com
48
Easy Topog-E® Boiler Installation Instructions
1. Remove old gasket and thoroughly clean the surface on boiler and on cover plate. Sometimes it is necessary to buff each surface. 2. Place Topog-E® Gasket on handhole cover plate. Be sure the gasket is pushed down tight on the plate. Do not use any grease, lubricant, or adhesive.
3. After cover plate is in boiler and gasket is in place, make one last cleaning swipe of the mating surface in the boiler. Use a rag wrapped around your finger.
4. Set crab, then center plate in opening and tighten nut enough to give a snug fit. Then, snug up with 1/4 turn of wrench.
SPECIAL NOTES:
• If gasket leaks while pressure is being built up, tighten only enough to stop leakage. Never over-compress a gasket.
• Gaskets on the bottom of a boiler shell are usually hard to install without leaking because particles of scale or sand tend to run down onto the mating surface between the time the surface is cleaned and the handhole cover plate is put into place ready
Lattner Boiler Company Instruction Manual – WLF Models February 2005 49
to be tightened. When this happens, drain the boiler again and start over, or expect to replace the gasket in a very short time.
• As pressure builds up in the boiler the bolt and crab will loosen. It takes some time for the gasket to reach its ultimate compression, so the operator should watch this for several days and keep the bolt tight until it no longer loosens. This is especially true if the boiler is operated intermittently; i.e., shut off at night to allow pressure to drop. In this case, vacuum pressure in the boiler would suck the cover plate in and allow the water to leak out of the boiler.
• Re-using gaskets after they have been in service is not recommended!
Topog-E® Bolt Gaskets (when required) should be used with Topog-E® Handhole Gaskets. Topog-E® Gaskets are sold for use in steam, water, air, and other selected applications only. Recommendations for use of Topog-E Gaskets are based on tests believed to be reliable and on actual customer experience. Since their installation and use is beyond our control we cannot guarantee the results, whether or not such use is in accordance with directions. We disclaim any responsibility.
1224 North Utica Tulsa, OK 74110-4682 1-800-587-7123 918-587-6649 Fax: 918-587-6961 [email protected]
Lattner Boiler Company Instruction Manual – WLF Models February 2005
L404A-D,F; L604A,L,M Pressuretrol® Controllers L404 and L604 Pressuretrol® Controllers are line voltage pressure controllers that provide oper- ating control, automatic limit protection, or manual reset limit protection for pressure systems of up to 300 psi (21.1 kg/cm2 or 2068 kpa).
■ Can be used with steam, air, non-combustible gases, ■ Screw adjustments made on top of case. or fluids non-corrosive to the pressure sensing ele- ■ Scaleplates marked in English (psi) and Metric ment. (kg/cm2) units. ■ Stainless steel diaphragm (except 300 psi [21.1 kg/ ■ L404F models available with European enclosure, cm2 (2068 kPa)] models) also allows use with am- British Standard Pipe Threads, ground screw, and monia, oxygen, distilled water, and similar media. scaleplates marked in kg/cm2 and either psi or kPa. ■ L404B is recommended for supervision of atomiz- ■ Clear plastic cover on case to observe pressure set- ing medium pressure in oil burner systems. tings and switch action. ■ Models are available with spst, spdt, or dpst switch- ■ Leveling indicator visible through cover. ing and in variety of operating ranges. ■ Hexagonal fitting with 1/4-18 NPT internal threads ■ Dustproof, trouble-free mercury switches (all mod- for direct mounting to 14026 Steam Trap (siphon els except L404F, which has snap-acting switch). loop). ■ Automatic reset models have adjustable, subtractive ■ Surface mount is available using screws through differential (except L604M). holes (knockouts) in case backing. ■ Trip-free mechanism on manual reset models as- sures that limit function of controller cannot be defeated by jamming reset lever.
CONTENTS Specifications ...... 2 Ordering Information ...... 2 Installation ...... 5 Setting and Checkout...... 8 Service Information ...... 10
L. Z. • Rev. 3-95 • ©Honeywell Inc. 1995
60-2150-10 L404A-D,F; L604A,L,M SPECIFICATIONS • ORDERING INFORMATION Specifications
TRADELINE® MODELS is available, except where noted in Table 1. The steam TRADELINE® models are selected and packaged to trap is necessary for boiler installations. provide ease of stocking, ease of handling, and maximum SWITCH(ES): Mercury switch(es) in all models except the replacement value. Specifications of TRADELINE® con- L404F, which has a Micro Switch snap-acting switch. trols are the same as those of standard models except as PRESSURE SENSING ELEMENT: Stainless steel dia- 2 noted below. phragm (brass bellows in 300 psi [21.1 kg/cm , (2068 kPa)] models). TRADELINE® MODELS AVAILABLE: MAXIMUM AMBIENT TEMPERATURE: 150°F (66°C). L604A Pressuretrol® Controllers—Available in 2 to 15, 5 to MINIMUM AMBIENT TEMPERATURE: Minus 35°F 50, 10 to 150, and 20 to 300 psi (.14 to 1.1 kg/cm2 [14 to (minus 37°C); also refer to the note in the Location and 103 kPa], .4 to 3.5 kg/cm2 [34 to 345 kPa], .7 to 10.6 kg/ Mounting section. cm2 [69 to 1034 kPa], and 1.4 to 21.0 kg/cm2 [138 to ADJUSTMENT MEANS: Screws on top of controller case. 2068 kPa]) . Scales are marked in psi and kPa. ADDITIONAL FEATURES: TRADELINE® pack with ELECTRICAL CONNECTIONS: Internal screw terminals; cross-reference label. hole in side of case for 1/2 in. conduit. MOUNTING MEANS: Hexagonal fitting on diaphragm has STANDARD MODELS 1/4-18 NPT internal threads for mounting on a pipe or MODELS: L404A-D,F and L604A,L,M Pressuretrol® Con- steam trap (siphon loop). Also can be surface-mounted trollers. See Table 1. A 14026 Steam Trap (siphon loop) using screws through two holes (knockouts) in back of case.
Ordering Information
When purchasing replacement and modernization products from your TRADELINE® wholesaler or distributor, refer to the Tradeline Catalog or price sheets for complete ordering number, or specify— 1. Order number (TRADELINE® model, if desired). 2. Operating range (see Table 1). 3. Model without steam trap, if desired and available (see Table 1, Note b). 4. Optional specifications, if desired (see Table 1). 5. Replacement parts, if desired. 6. Accessories, if desired.
If you have additional questions, need further information, or would like to comment on our products or services, please write or phone: 1. Your local Home and Building Control Sales Office (please check the white pages of your phone directory). 2. Home and Building Control Customer Logistics Honeywell Inc., 1885 Douglas Drive North Minneapolis, Minnesota 55422-4386 (612) 951-1000 In Canada—Honeywell Limited/Honeywell Limitée, 740 Ellesmere Road, Scarborough, Ontario M1P2V9. International Sales and Service Offices in all principal cities of the world. Manufacturing in Australia, Canada, Finland, France, Germany, Japan, Mexico, Netherlands, Spain, Taiwan, United Kingdom, U.S.A.
60-2150—10 2 L404A-D,F; L604A,L,M SPECIFICATIONS
TABLE 1—MODELS AVAILABLE. Switching Action on Midscale Subtractive Differentiala Maximum Surge Pressure Rise Operating Rangesa (Adjustable) Pressure Model to Setpoint psi kg/cm2 kPa psi kg/cm2 kPa psi kg/cm2 kPa L404A spst, breaks 2 to 15b,c .14 to 1.0 14 to 103 2 to 6 .14 to .41 14 to 4 50 3.5 345 circuit 5 to 50 .35 to 3.5 34 to 345 4 to 12 .28 to.82 127 to 83 85 6.0 586 10 to 150b .66 to 10.6 69 to 1034 8 to 16 .56 to 1.10 55 to 110 225 15.8 1550 20 to 300d 1.4 to 21.0 138 to 2068 15 to 40 1.04 to 2.76 103 to 276 500 35.2 3445 L404Bi spst, makes 2 to 15d,c,e,f .14 to 1.1 14 to 103 2 to 6 .14 to .41 14 to 41 50 3.5 345 circuit 5 to 50 .35 to 3.5 24 to 345 4 to 12 .28 to .82 27 to 83 85 6.0 586 10 to 150e,b .66 to 10.6 69 to 1034 8 to 16 .56 to 1.10 55 to 110 225 15.8 1550 20 to 300d 1.4 to 21.0 138 to 2068 15 to 40 1.04 to 2.76 103 to 276 500 35.2 3445 L404C spst, breaks 2 to 15 .14 to 1.0 14 to 103 manual reset 50 3.5 345 circuit 5 to 50 .35 to 3.5 34 to 345 (fixed, subtractive differential) 85 6.0 586 10 to 150 .66 to 10.6 69 to 1034 225 15.8 1550 20 to 300d 1.4 to 21.0 138 to 2068 500 35.2 3445 L404D spst, makes 2 to 15 .14 to 1.0 14 to 103 manual resetg 50 3 5 345 circuit 10 to 150 .66 to 10 69 to 1068 (fixed, subtractive differential) 225 15.8 1550 L404F spdt snap-acting 2 to 15 .14 to 1.0 14 to 103 2 to 6 .14 to .41 14 to 41 50 3.5 345 switch,h makes 5 to 50i .35 to 3.5 34 to 345 6 to 14 .41 to .97 41 to 97 85 6.0 586 R-W, breaks R-B 10 to 150 .66 to 10 69 to 1034 10 to 22 .69 to 15.2 60 to 152 225 15.8 1550 20 to 300d 1.4 to21.0 138 to 2068 20 to 50 1.4 to 3.5 138 to 345 500 35.2 3445 L604A 2 isolated spst 2 to 15c .14 to 1.0 14 to 103 2 to 6 .14 to .41 14 to 41 25 1.8 172 circuits, or 1 5 to 50 .35 to 3.5 34 to 345 4 to 12 .28 to .82 27 to 83 85 6.0 586 spdt,j makes R1- 10 to 150 .66 to 10 69 to 1034 8 to 16 .56 to 1.10 55 to 110 225 15.8 1550 W, breaks R2-B 20 to 300d 1.4 to21.0 138 to 2068 15 to 40 1.04 to 2.76 103 to 276 500 35.2 3445 L604L spdt circuit 2 to 15 .14 to 1.0 14 to 103 manual resetg 25 1.8 172 makes R-W, (fixed, subtractive differential) breaks R-B L604M spdt circuit 10 to 150 .66 to 10.1 69 to 1034 fixed: 3.5 psi (24.1 kPa) 225 15.8 1550 makes R-W, breaks R-B a Scaleplates are marked in both psi and kg/cm2 b Model available with special fixed low differential. Switch rated for 0.5A at 120 Vac. c L404A,B and L604A models are available with 1 to 6 psi midscale subtractive differential in 2 to 15 psi models. d Brass bellows replaces stainless steel diaphragm. Not suitable for use with ammonia, oxygen, or other corrosive materials. e Model available with minimum operating pressure of 1.25 psi (0.09 kg/cm2 or 8.62 kPa) and minimum subtractive differential of 0.5 psi (0.035 kg/cm2 or 3.45 kPa). f Model available with special fixed low differential. Switch rated for 0.5A at 120 Vac. g L404C,D and L604L models are designated as Manual Reset 2 controllers; the trip-free reset mechanism does not permit the controller to function as an automatic-reset device when the manual reset lever is held in the reset position. The subtractive differential is fixed at the minimum value of the adjustable differential of the L404A for each corresponding operating range. h L404F only; all other models have mercury switches. i Model available with sealed bell crank adjustment. j Spst switches operate in unison; spdt action when jumper is installed between R1 and R2. k Also recommended for supervision of atomizing medium pressure (air or steam) in an oil burner system.
SWITCH CONTACT RATING (in amperes at 50/60 Hz): Model Load 120 Vac 240 Vac 120 Vdc 240 Vdc L404A Full Load 8.0 5.1 2.4 1.2 Locked Rotor 48.0 30.6 24.0 12.0 Noninductivea 10.0 5.0 5.0 2.0 L604A,Lb Full Load 8.0 5.1 2.0 1.0 Locked Rotor 48.0 30.6 20.0 10.0 Noninductive 10.0 5.0 8.0 4.0 L604M Full Load 1.0 0.5 1.0 0.5 a L404F (snap-acting) does not have non-inductive or dc ratings. b L604A and L have also been tested (and listed by Underwriters Laboratories Inc.) and breaking (not making) a load with a total rating of 9.8 A full load, plus 360 VA ignition, plus 250 VA pilot duty at 120 Vac.
3 60-2150—10 L404A-D,F; L604A,L,M SPECIFICATIONS
DIMENSIONS: See Fig. 1. See Fig. 2 for mounting steam REPLACEMENT PARTS: trap (siphon loop). 129178 Thermoplastic Cover. WEIGHT: 2 IBC. (0.91 kg). 14026 Steam Trap (siphon loop)—1/4 in. black iron pipe. FINISH: Gray. Necessary for boiler installations. APPROVALS: ACCESSORIES: Underwriters Laboratories Inc. listed (L404A,B,C,D,F; 33312B Knurled Adjustment Knob—with setscrew; fits L604A,L,M only): file no. MP466, vol.10; guide on main scale pressure adjusting screw. no. MBPR. 4074BWJ Limit Stop Assembly—to limit set point ranges; Canadian Standards Association certified (L404A,B,C,D,F; includes 129564 Range Stop, 107194 Range Stop L604A,L only): file no. LR1620; guide no.400-E-0. Screw, and 23466 Wrench.
TABLE 2—CONVERSION TABLE (psi to kPa). Operating Range Subtractive Differential Scale-Plate Equivalent Scale-Plate Equivalent (psi) (kg/cm2) (kPa) (psi) (kg/cm2) (kPa) 0 to 15 0 to 10 0 to 103 — — — 2 to 15 .14 to1.0 14 to 103 1 to 6 07 to 4 7 to 41 2 to 6 .14 to .4 14 to 41 5 to 50 .3 to 3.5 34 to 345 4 to 12 .3 to .8 28 to 83 5 to 14 .4 to 1.0 41 to 97 5 to 150 .3 to 10.3 34 to 1034 — — — 10 to 150 .7 to 10.3 69 to 1034 8 to 16 .6 to 1.1 55 to 110 10 to 22 .7 to 1.5 69 to 152 20 to 300 1.4 to 20.7 138 to 2068 15 to 40 1.0 to 2.8 103 to 276 20 to 50 1.4 to 3.5 138 to 345
Fig. 1—Mounting dimensions of the L404A,B,C,D,F and L604A,L,M Pressuretrol® Controllers, in in. (mm). L404A-D,F; L604A,L,M
4-1/2 (114.3) (COVER) 2-3/4 (69.9) 4-11/32 (110.3) (CASE) 1-1/16 (27.0) 1-15/16 (49.2) 1-61/64 (49.6) 13/16 3-3/16 (81.0) 1/2 (12.7) 1 (20.6) 1-5/32 (29.4) 1
3-7/8 3-23/32 (98.4) (94.5)
4-31/32 (126.2)
2 1-13/16 (46.0) 13/16 (20.6) 3
7/8 3/16 (4.8) X 21/64 (8.3) (22.2) DIA. KNOCKOUT (2)
1-1/16 2-1/8 (54.0) 1/4-18 NPT (27.0) 1-3/16 (30.2)
1-1/2 (38.1) 1 RESET LEVER (ON MANUAL RESET MODELS ONLY.)
2 THIS DIMENSION IS 4-27/32 IN. (123.0 MM) ON L604 MODELS WITH A 2 TO 15 PSI (.14 TO 1.0 kg/cm2 (14 TO 103 kPa)) OPERATING RANGE, AND 5-3/4 IN. (146.A MM) ON L604 MODELS WITH A 20 TO 300 PSI (1.4 TO 20.7 kg/cm2 (138 TO 2068 kPa) OPERATING RANGE.
3 ONLY ON L604 MODELS WITH A 2 TO 15 PSI (.14 TO 1.0 kg/cm2 (14 TO 103 kPa)) OPERATING RANGE. M8933
60-2150—10 4 L404A-D,F; L604A,L,M INSTALLATION
Installation
WHEN INSTALLING THIS PRODUCT. . . 1. Read these instructions carefully. Failure to follow Fig. 2—Right and wrong mounting of a steam them could damage the product or cause a hazardous trap (siphon loop), with approximate dimen- condition. sions in in. (mm).
2. Check the ratings given in the instructions and on the PRESSURE product to make sure the product is suitable for your PRESSUR GAUGE application. CONTROLLER 3. Installer must be a trained, experienced, flame safe- guard control technician. 4. After installation is complete, check out product operation as provided in these instructions. TEE CAUTION 2-1/4 14026 1 (57.2) 1. Disconnect power supply before beginning in- STEAM TRAP DIA. stallation to prevent possible equipment dam- 4-1/2 TO 5-1/2 (SIPHON LOOP) (114.3 TO 139.7) age or electrical shock. CORRECT 2. When using the controller with a compressor, INCORRECT install a dampening device (such as a needle valve, header, or surge tank) to dampen pulsations that BOILER BOILER can damage the controller or reduce its life.
1 1/4 IN. BLACK IRON PIPE WITH 1/4 - 18 NPT EXTERNAL IMPORTANT: TRHEADS ON BOTH ENDS. BEND THE STEAM TRAP 1. Locate the controller where the ambient temperature (SIPHON LOOP) TO LEVEL THE CONTROLLER. M8934 will not exceed 150°F (66°C). 2. Use pipe compound sparingly to avoid clogging the Make all pipe connections in accordance with approved hole in the pipe or diaphragm fitting. standards. Use only a small amount of pipe compound to 3. Do not tighten the controller by hand by holding the case. seal the connection joints. Excess pipe compound can clog 4. Accurately level the controller for proper operation. the small hole in the fitting and prevent the controller from operating properly. LOCATION AND MOUNTING To avoid leaks and damage to the case, use a parallel jaw wrench on the controller’s hexagonal fitting. Do not tighten NOTE: For most accurate operation; add supplemental heat the controller by hand by holding the case. to installations where the temperature falls below minus 20°F (minus 29°C). Never locate the controller where the ° ° Leveling temperature falls below minus 35 F (minus 37 C), be- A controller with a mercury switch must be accurately cause mercury in the switch freezes at this temperature. leveled for proper operation. It is level when the leveling indicator (Fig. 11) hangs freely with its pointer directly When used with steam boilers, always mount the con- over the index mark inside the back of the case. Level the troller above the water line in the boiler. A steam trap controller by carefully bending the steam trap (siphon (siphon loop) must always be connected between the con- loop). troller and the boiler (Fig. 2) to prevent boiler scale and corrosive vapors from attacking the diaphragm. The loop Mounting Alongside a Pressure Gauge on the steam trap must always be perpendicular to the face To mount the controller alongside a pressure gauge of the controller. If the loop is parallel to the controller, (Fig. 2), remove the gauge. In its place, install a steam trap expansion or contraction of the loop tips the controller and (siphon loop) with a tee on top. Using elbows and pipe causes the switch to operate inaccurately. nipples, mount the controller and pressure gauge on the The controller can be mounted (1) alongside the pres- ends of the tee. Level the controller after installation. sure gauge, (2) in a fitting on the boiler provided by the manufacturer, (3) at a remote location in case of excessive vibration, or (4) in a special mounting on a low water cutoff.
5 60-2150—10 L404A-D,F; L604A,L,M INSTALLATION
Mounting on a Boiler If it is not convenient to mount the controller alongside Fig. 3—L404 terminal blocks and internal the pressure gauge, install a steam trap (siphon loop) in the schematics.
fitting provided by the boiler manufacturer. If there is no RISE fitting, mount the steam trap at a location recommended by RISE RISE the boiler manufacturer. Screw the controller directly to the B steam trap, and level the controller. W R R
Mounting at a Remote Location R W
If there is excessive vibration at the boiler that can W B
adversely affect the operation of the controller, mount the B controller at a remote location. All piping from the boiler must be suitable and solidly mounted. The piping must be L404A,C L404B,D L404F (SNAP-ACTING) properly pitched to drain all condensation back to the BREAKS ON MAKES ON BREAKS R-B, boiler. A steam trap (siphon loop) must be mounted be- PRESSURE RISE PRESSURE RISE MAKES R-W ON TO SETPOINT TO SETPOINT PRESSURE RISE tween the remote piping and the controller. Level the TO SETPOINT controller after installation. M8941
Supervision of Atomizing Medium Pressure (Air or Steam)—L404B Fig. 4—L404 terminal block and internal When air or steam is used as an atomizing medium in an schematic. oil burner system, authorities having jurisdiction (approval bodies and codes) often require a low limit to prevent opening the main oil valve until sufficient atomizing pres- RISE RISE sure is present, and to shut down the system when the
atomizing pressure falls too low. B B The L404B is recommended for this application. It R2 R makes a circuit when the pressure rises to the set point, and 1 breaks when the pressure falls to the set point minus the JUMPER R1 W differential (Fig. 10). W
WIRING 1. Disconnect the power supply before beginning wiring L604A L604L,M to prevent electrical shock or equipment damage. MAKES R1-W BREAKS R2-B 2. Assume all wiring complies with applicable electrical ON PRESSURE RISE TO SETPOINT. 1 SPDT SWITCH ACTION WITH JUMPER INSTALLED; codes, ordinances, and regulations. Use NEC Class 1 (line M8935 voltage) wiring. OTHERWISE, TWO ISOLATED SPST SWITCHES. 3. For normal installations, use moisture-resistant No. 14 ° ° wire suitable for at least 167 F (75 C) when you are using Fig. 5—L404 used as a limit or as an operating the controller with a flame safeguard primary control, or at controller. least 194°F (90°C) when using it with a programming SPST control. CONTROLLER 4. For high temperature installations, use moisture-resis- 2 tant No. 14 wire, selected for a temperature rating above the L1 FLAME (HOT) maximum operating temperature. SAFEGUARD CONTROL, 5. All models have a terminal block inside the cover (Fig. POWER 1 SUPPLY MOTOR, OR 3 and 4) and a 7/8 in. (22.2 mm) hole in one side for 1/2 in. OTHER LOAD conduit, cable, or wires. Remove the front cover by loosen- L2 L2 ing the screw at the bottom of the main scale. 6. Refer to Fig. 5 through 9 for typical hookups. Follow the burner or boiler manufacturer’s wiring diagram if pro- 1 PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION vided . AS REQUIRED. 7. Make sure the loads do not exceed the Switch Contact 2 HIGH LIMIT—L404A OR C BREAKS WHEN PRESSURE RISES TO SETPOINT. Ratings in the Specifications section. LOW LIMIT—L404B BREAKS WHEN PRESSURE FALLS TO SETPOINT MINUS DIFFERENTIAL. 8. Replace the front cover when wiring is completed. OPERATING CONTROLLER—L404A BREAKS WHEN PRESSURE RISES TO SETPOINT, AND MAKES AGAIN WHEN PRESSURE FALLS TO SETPOINT MINUS DIFFERENTIAL. M8936
60-2150—10 6 L404A-D,F; L604A,L,M INSTALLATION
Fig. 6—L404 with a low voltage relay. Fig. 8—L404F, L604A (with jumper installed) or L604M, used as a low limit, with an alarm circuit.
LOW VOLTAGE RELAY SPDT L404 CONTROLLER L1 (HIGH LIMIT) 1 (HOT) 24 VOLT POWER 1 2 THERMOSTAT SUPPLY 2 L2 W B
R
L1 FLAME (HOT) THERM SAFEGUARD CONTROL, POWER 1 SUPPLY MOTOR, OR OTHER LOAD L2 L2
LOAD
ALARM 1 PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED. M8940 1 PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.
2 BREAKS R TO B AND MAKES R TO W WHEN PRESSURE RISES TO SETPOINT. M8938
Fig. 7—L404F, L604A (jumper installed) used as a high limit, with an alarm circuit. Fig. 9—L404F, or L604 with jumper installed, controlling an M644B motor. SPDT CONTROLLER (LOW LIMIT)
SPDT LINE VOLTAGE 2 CONTROLLER TWO-POSITION MOTOR W B WHITE W W1 CLOSED R (LOW FIRE) RED 2 R R1 L1 FLAME (HOT) SAFEGUARD BLUE CONTROL, B B1 OPEN POWER 1 (HIGH FIRE) SUPPLY MOTOR, OR OTHER LOAD L2 L2 L1 BLACK (HOT) L1 POWER ALARM SUPPLY 1 BLACK L2 L2 M644B 1 PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.
2 BREAKS R TO W AND MAKES R TO B WHEN PRESSURE 1 PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION FALLS TO SETPOINT MINUS DIFFERENTIAL. M8937 AS REQUIRED.
2 BREAKS R TO B AND MAKES R TO W WHEN PRESSURE RISES TO SETPOINT. M8939
7 60-2150—10 L404A-D,F; L604A,L,M SETTING AND CHECKOUT Setting and Checkout
SETTING main scale setpoint. They will not automatically return to In all models, the differential is subtractive from the their former positions. To reset one of these controllers, main scale set point. The upper operating point is deter- wait until the pressure falls to the set point minus the mined by the main scale set point, while the lower operat- differential (Fig. 10). Then depress the manual reset lever ing point is determined by the main scale setting less the (Fig. 11) and release it. The controller will not be reset until differential setting. The L404F and L604A (with jumper you release the manual reset lever. This prevents the con- installed), L,M have spdt switching action. Operating points troller from becoming an automatic-reset device if the reset are shown in Fig. 10. lever is stuck, held in, or tied down.
Fig. 10—L404 and L604 operating points. Fig. 11—Setting a Pressuretrol® Controller.
MAIN SCALE SETPOINT (SWITCH BREAKS) DIFFERENTIAL ADJUSTING MANUAL L404A,C SUBTRACTIVE SCREW 1 RESET DIFFERENTIAL LEVER PRESSURE MAIN SCALE RISE SCALEPLATES ADJUSTING DIFFERENTIAL SETTING 2 1 SCREW MERCURY (SWITCH MAKES) SWITCH
MAIN SCALE SETPOINT (SWITCH MAKES) L404B,D SUBTRACTIVE DIFFERENTIAL PRESSURE DIFF. MAIN RISE 3.5 50 DIFFERENTIAL SETTING 1 12 3 (SWITCH BREAKS) .8 40 10 .7 2.5 8 .6 2 30 .5 MAIN SCALE SETPOINT 6 .4 1.5 20 1 4 .3 1 (BREAKS R-B, MAKES R-W) .2 10 2 .1 .5 L404F; SUBTRACTIVE 0 0 DIFFERENTIAL DIFFERENTIAL PSI L604L,M PRESSURE SETTING RISE DIFFERENTIAL SETTING INDICATOR 2 (MAKES R-B, BREAKS R-W)
MAIN SCALE SETPOINT (MAKES R1-W, BREAKS R2-B) MAIN SCALE INDEX SUBTRACTIVE SETTING L604A MARK DIFFERENTIAL INDICATOR PRESSURE POINTER RISE DIFFERENTIAL SETTING DIAPHRAGM (BREAKS R1-W, MAKES R2-B) ASSEMBLY LEVELING INDICATOR 1 ADJUSTABLE DIFFERENTIAL ON THE L404A,B,F; L404L WITH A 5 TO 1 L404C,D AND L604L MANUAL RESET MODELS HAVE A SMALL, FIXED 2 DIFFERENTIAL. THEY CAN BE MANUALLY RESET WHEN THE PRESSURE 150 PSI (0.34 TO 10.3 kg/cm [34 TO 134 kPa] OPERATING RANGE; FALLS TO THE MAIN SCALE SETPOINT MINUS THE DIFFERENTIAL. AND L604A MODELS ONLY.
2 L604M HAS A SMALL, FIXED DIFFERENTIAL OF 3.5 PSI (0.25 kg/cm2) 2 TRIP-FREE MANUAL RESET LEVER ON THE L404C,D AND L604L OR 24.1 kPa.) M8942 MODELS ONLY. M8943
Adjust the main scale set point for the desired operating CHECKOUT pressure by turning the main scale adjusting screw (Fig. 11) on the top of the case until the main scale setting indicator After the controller has is installed, wired, and set, test it with the system in operation. First allow the system to is at the desired value. On an L404A,B,F with a 5 to 150 psi stabilize. Then observe the operation of the controller while (.3 to 10.3 kg/cm2 [34 to 1034 kPa]) operating range, or an L604A, adjust the differential setting by turning the dif- raising and lowering its setpoint. Pressure should increase when the setpoint is raised and decrease when the set point ferential adjusting screw (Fig. 11) until the differential is lowered. setting indicator is at the desired value. L404C,D and L604L are manual reset models: see the next paragraph. Also check the make and break points of the controller. If they do not agree with a separate, accurately calibrated The L604M has a fixed differential. The scaleplates are pressure gauge, a slight adjustment of the scaleplate(s) may marked psi and kg/cm2. be necessary. Use accurate pressure testing equipment when checking Trip-Free Manual Reset Feature out the controller. Do not rely on inexpensive gauges. The (L404C,D and L604L only) The L404C breaks, the L404D makes, and the L604L controllers are carefully calibrated at the factory. makes R-W and breaks R-B when the pressure rises to the
60-2150—10 8 L404A-D,F; L604A,L,M SETTING AND CHECKOUT
Boiler Installation If the controller is being used on a boiler installation, test CAUTION it as follows: Do not put the system into service until you have 1. Note the boiler pressure by checking the boiler pres- satisfactorily completed all applicable tests de- sure gauge. (To perform this test properly, the boiler should scribed in this Checkout section, in the Checkout have a pressure reading near the middle of the controller’s section of the applicable instructions for the flame main scale range.) safeguard control, and any others required by the 2. Turn the main scale adjusting screw (Fig. 11) until the burner and boiler manufacturers. main scale setting indicator on the controller corresponds to the boiler pressure gauge reading. 3. The L404A or C should break the control circuit(s) Fig. 12—Checking controller operation using automatically when the boiler pressure gauge reading equals an ohmmeter. or slightly exceeds the controller setting. The L404B or D should make the circuit under the same circumstances. MAIN SCALE The L404F; L604L,M should make the R-W circuit and ADJUSTING SCREW break the R-B circuit under the same circumstances. The L604A should make the R1-W circuit and break the R2-B circuit under the same circumstances.
4. If the controller is operating properly, turn the main DIFF. MAIN 3.5 50 scale adjusting screw (Fig. 11) until the main scale setting 3 12 .8 40 10 .7 2.5 indicator is at the desired set point. 8 .6 2 30 .5 DIFFERENTIAL 6 .4 1.5 20 SETTING 4 .3 1 B .2 10 R1 R2 INDICATOR 2 .1 .5 W If a Controller Seems to Operate Improperly 0 0
PSI KG PSI CM 2 KG If the controller is suspected of operating improperly, it CM 2 MAIN SCALE DIFF. IS SUBTRACTIVE may be further checked as follows (Fig. 12): SETTING 1. Disconnect all power to the controller, loosen the INDICATOR cover screw, and remove the cover. 2. Disconnect the wires from the controller. 3. Connect an ohmmeter between the switch terminals. 4. Lower the set point of the controller (simulating a pressure increase) through a range greater than the differen- tial. The switch should either make or break, depending on the model of the controller. (An L404A or C should break, an OHMMETER L404B or D should make, an L404F; L604L,M should break SETPOINT INPUT OUTPUT R-B and make R-W, and an L604A should break R2-B and DECREASE make R1-W.) If it makes, the ohmmeter reads zero; if it breaks, the ohmmeter reads infinity. 0 5. Raise the set point of the controller (simulating a W B pressure decrease) through a range greater than the differen- 1 tial. The switch should break or make, just the opposite of its R action in step 4 (except for the L404C,D and L604L manual ZERO reset models). ADJ
ZERO OHMS NOTE: An approximation of the differential can be made by (INFINITY WHEN R-B BREAKS) observing the change in set point required for a resistance 1 AN L604, WITH JUMPER INSTALLED BETWEEN R1 AND R2, IS SHOWN; change from zero to infinity. AN L404F OPERATES SIMILARLY (SPDT SWITCHING). AN L404A, B, C OR D HAS ONLY TWO TERMINALS (SPST SWITCHING); AN L404A OR C BREAKS AND L404B OR D MAKES WHEN THE SETPOINT IS DECREASED FAR ENOUGH. 6. If the controller operates improperly, replace it. M8944 7. When the controller is operating properly, reconnect the wires to the terminal block, replace the cover and tighten the cover screw, and reconnect the power.
9 60-2150—10 L404A-D,F; L604A,L,M SERVICE INFORMATION
Service Information
CALIBRATION MAINTENANCE The controller was carefully calibrated during manufac- The cover of the controller should be in place at all times turing and should not require recalibration. Most calibra- to protect the internal components from dirt, dust, and tion errors are caused by improper leveling. The controller physical damage. Routine maintenance should consist of should be level when the pointer on the leveling indicator is occasional inspection and blowing or brushing away any directly over the index mark (Fig. 11). In some cases, the accumulated dirt and dust. To ensure proper functioning of leveling indicator may not be accurate enough. The pointer the controller at all times, perform an operational check of may be over the index mark, but the controller still may not the entire system during routine maintenance checks. be operating within the tolerance of its scale setting. In this case, carefully bend the steam trap (siphon loop) until the controller switches properly.
60-2150—10 10 KUNKLE PRESSURE RELIEF VALVES Installation and Operating Instructions
Pre-Installation Handling This pressure relief valve is designed to protect equipment from overpressure. The valve should be handled with care, not subjected to heavy shock loads, and protected to prevent contamination from getting inside. It should be installed correctly per A.S.M.E. Boiler & Pressure Vessel Code requirements. Failure to do so could result in property damage or serious injury to personnel. When hoisting the valve into position for installation, care should be exercised so that lifting straps do not contact the valve lift lever.
Installation Always wear proper safety equipment, including safety glasses and ear protection.
1. Mount the valve in a vertical position so that the valve body is self-draining. If a body drain port is provided, make sure it is open when required by the ASME code. Do not plug any bonnet vent openings. The inlet piping should be as short as possible, with no elbows, and equal to or greater than the size of the pressure relief valve inlet connection. This will help to limit the inlet pressure drop to 3% or less when the valve is relieving.
2. When discharge piping is connected to valve outlet, make sure it is self draining if a body drain port is not used. The valve should not be connected to any discharge pipe that contains pressure before the valve opens or to any pipe where the pressure build-up is greater than 10% of the set pressure when the valve is open and relieving.
Discharge piping, other than a short tailpipe, must be supported. For steam service, a drip pan elbow or flexible connection between the valve and the pipe should be used to prevent excessive pipe stress, due to thermal expansion, from being imposed on the valve body.
3. For threaded valves, to prevent sealing compound from entering and damaging the valve, apply a small amount of pipe thread sealing compound to external threads only. Do not put any sealing compound on the first thread or on any internal threads. To do so may cause the sealing compound to enter the valve and cause seat leakage.
Do not use the valve body or bonnet for installing the valve in threaded connections. Use the wrench flats provided to tighten the valve to the connecting pipe, and do not overtighten. To do so may cause valve leakage.
4. For flanged valves, use new gaskets and tighten the mounting studs evenly.
Operation 1. Maintain a system operating pressure at least 5 psig or 10% below the set pressure of the valve, whichever is greater. Operating too close to the valve set pressure will cause seat leakage and will shorten the time between valve maintenance.
2. Do not use the safety valve as a control valve to regulate system operating pressure. Excessive operation will cause the seat to leak and will require more frequent valve maintenance.
3. ASME Section I and VIII valves equipped with lift levers are designed to be operated only when the system pressure is 75% of set pressure or greater. ASME Section IV valves may be operated at any set pressure. When hand operating the valve, hold it open long enough to purge any foreign matter from the seat area. If a cable or wire is attached to the lift lever for remote actuation, make sure the direction of pull is the same as it would be if the lever were pulled directly by hand.
Maintenance Maintenance should be performed on a regular basis. An initial inspection interval of 12 months is recommended. Depending on the service conditions and the condition of the valve, the inspection interval may be decreased or increased. Use only Kunkle parts for repair. Depending on the local jurisdictional requirements where the valve is installed, repairs may have to be made by a repair facility holding a VR stamp. WARNING! Removal of the seal wires or any attempt to adjust, repair or modify this product by non-qualified or non-authorized persons voids the product guarantee and may cause serious damage to equipment, personal injury, and death. Kunkle Valve is not liable for any damage resulting from misuse or misapplication of its products.
Kunkle Valve Division Rev B 01/14/2002 Phone: 828-669-5515 953 Old US 70, Black Mountain, NC 28711 Fax: 828-669-4017
BULLETIN MS2056- 04/04
Gas Appliance Pressure Regulators Straight-Thru-Flow Design RV52, RV53, RV61, RV81, RV91, RV111, and RV131 1/2", 3/4", 1", 1¼", 1½", 2", 2½", 3" & 4"
design certified
Maximum Pressure CSA Rated (except RV131) ...... 1/2 psi (35 mbar) Maxitrol Tested* RV52 & RV53 ...... 1/2 psi (35 mbar) RV61, RV81, RV91, & RV111 ...... 1 psi (70 mbar) RV131 ...... 2 psi (140 mbar) * Do not use if inlet pressure is more than 10 times desired outlet pressure
EMERGENCY EXPOSURE LIMITS (Maxitrol Tested) RV52 & RV53 ...... 3 psi (210 mbar) RV61, RV81, RV91 & RV111 ...... 5 psi (350 mbar) RV131 ...... 15 psi (1050 mbar)
GAS CONTAINMENT EXPOSURE LIMITS* RV 52 & RV53 ...... 15 psi (1050 mbar) RV61, RV81, RV91, RV111, & RV131 ...... 25 psi (1750 mbar) * Please note that internal damage may occur when exposed to these pressures. AMBIENT TEMPERATURE LIMITS S-T-F Series RV52, RV53, RV61, RV81, RV91 & RV111 ...... -40° to 205° F (-40° to 96° C) RV131 ...... -40 to 125° F (-40 to 52° C) ......
GASES: Natural, manufactured, mixed, liquefied petroleum, or LP gas-air mixture. Straight-Thru-Flow Design
RV52, RV53, RV61, RV81, RV series RV91, RV111, and RV131 FEATURES • Greater accuracy—higher pressure drop capacity • Outlet pressures available to 42” w.c. • Available in full range of pipe sizes from 1/2" to 4" • All models tapped with NPT vent bosses • CSA Design Certified (except RV131) BENEFITS • Unique conical valve design fills need of combining good regulation with high capacity in low to intermediate pressure range • Allows more pressure drop to be assigned to piping and valves—permits reduction in manifold size • Provides accurate, sensitive regulation at inlet pressures as low as 3” w.c. • RV131 only, provides bonus benefits of high capacity and good performance at pressures of 1 psi or higher • Ease of installation and replacement
All models except RV131 are CSA design certified for 1/ RV131 four inch model is of cast iron and steel 2 psi rated pressure under the ANSI standard for gas construction. RV61, RV81, RV91, RV111, & RV131 pressure regulators; and CSA listed to certify compliance internal conical valves are coated with Teflon® for with nationally published safety, construction, and long life. Diaphragm material is cut from the finest performance standards. synthetic coated fabrics available. All other parts are carefully specified corrosion-resistant or plated They are main burner only, non-lockup type. They material. should not be used as a line gas pressure regulator ahead of low pressure controls. Use only where Pipe sizes of 1/2”, 3/4”, 1”, 1-1/4”, 1-1/2”, 2”, 2-1/2", downstream controls can operate at line pressure. 3”, and 4” are available. Models through the 3" size Refer to other Maxitrol sales bulletins for proper are threaded, the 4" RV131 is flanged. types. At the emergency exposure limits, there may be no The RV52, RV53, & RV61 are suitable for multipoise regulation, but all models will contain gas. They will mounting. The RV81, RV91, RV111, & RV131 are suffer no internal damage and will resume regulation recommended for normal horizontal position only. when normal pressure is restored.
Maxitrol's original Straight-Thru-Flow design meets Straight-Thru-Flow appliance regulators are intended your needs for high capacities at low inlet pressures. for use with all fuel gases, and may also be used with The basic difference between S-T-F design and other air or other noncorrosive gases within their pressure type regulators lies in the conical valve. The cone limits. principal permits gas to flow straight through the regulator without changing directions. Frictional flow Typical applications include all types of residential, resistance is reduced, resulting in greater capacity. commercial and industrial gas-fired appliances and equipment used on low pressure gas supply. See The improved flow pattern provides accurate Maxitrol’s ”Spring Selection Chart“ for part numbers, sensitive regulation at extremely low pressure color and size of springs. differentials. The ability of the regulator to handle large capacity appliances with limited supply Teflon is a registered trademark of DuPont Corporation. pressure offers a definite advantage to designers of commercial and industrial gas-fired equipment. Models up to the three inch pipe size have high NOTE: All Maxitrol appliance regulators should be installed strength pressure cast aluminum housings. The in accordance with Maxitrol’s “Safety Warning” bulletin.
2 Capacities and Pressure Drop CAPACITIES—expressed in CFH (m3/h)—0.64 sp gr gas
Pressure Drop Ñinches w .c. (mbar) M odel A.G.A.CSA Number and Pipe Size MAX 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 2 3 4
1/2 x 1/2 450 151 214 262 302 338 370 400 427 453 478 676 828 956 RV52 3/4 x 3/4 (12.7) (4.2) (6.1) (7.4) (8.5) (9.5) (10.5) (11.3) (12.1) (12.8) (13.5) (19.1) (23.4) (27.1)
3/4 x 3/4 710 217 306 375 433 484 530 573 612 650 684 968 1185 1369 RV53 1 x 1 (20.1) (6.1) (8.6) (10.6) (12.2) (13.7) (15) (16.2) (17.3) (18.4) (19.3) (27.4) (33.5) (38.7)
1 x 1 1100 379 536 675 759 848 929 1004 1073 1138 1200 1742 2134 2464 RV61 1-1/4 x 1-1/4 (31.1) (10.7) (15.1) (19.1) (21.5) (24) (26.3) (28.4) (30.4) (32.2) (34.0) (49.3) (60.4) (69.8)
1-1/4 x 1-1/4 2500 780 1102 1350 1559 1743 1909 2062 2204 2339 2465 3485 4269 4929 RV81 1-1/2 x 1-1/2 (70.8) (22.1) (31.2) (38.2) (44.1) (49.5) (54) (58.4) (62.4) (66.2) (69.8) (98.7) (120) (139)
2 x 2 3275 1212 1714 2100 2424 2711 2969 3208 3429 3637 3834 5422 6640 7668 RV91 2-1/2 x 2-1/2 (92.7) (34.3) (48.5) (59.4) (68.6) (76.7) (84.1) (90.8) (97.1) (103) (108) (153) (188) (217)
2-1/2 x 2-1/2 7500 2742 3878 4750 5485 6132 6718 7256 7757 8227 8572 12134 14862 17161 RV111 3 x 3 (212) (78) (110) (134) (155) (175) (190) (205) (219) (233) (243) (343) (420) (486)
4734 6695 8200 9468 10586 11596 12525 13390 14202 14971 21172 25930 29942 RV131 4 x 4 -- (134) (190) (232) (268) (300) (328) (354) (380) (402) (424) (600) (734) (848) Sizing Instructions In order to select the proper size regulator, you must SOLUTION: know the available inlet pressure, desired outlet 1. Check capacity Chart above for 4" regulator, pressure, and the required maximum flow rate. RV131. 2. Note that at a flow rate of 21,172 CFH the Example No. 1—To select a regulator of ample pressure drop is 2" w.c. capacity to handle flow. 3. Multiply this by two to obtain recommended differential pressure (4" w.c.). KNOWN: 4. Subtract 4" differential pressure from 10" w.c. Pipe size 2-1/2", flow rate 8,000 CFH (0.64 sp gr), inlet inlet pressure to obtain maximum recommended pressure 9" w.c., desired outlet pressure 5" w.c. outlet pressure setting of 6" w.c.
SOLUTION: 1. Determine differential pressure available: Pressure Drop Chart Inlet pressure 9" w.c. Subtract outlet pressure - 5" w.c. Available differential pressure 4" w.c. 2. When determining capacity Maxitrol recommends that the pressure drop not exceed 1/2 of available differential pressure (1/2 of 4" w.c. = 2" w.c.). 3. Check Capacity Chart to determine which regulator has a pressure drop of 2" w.c. or less at a flow rate of 8,000 CFH. 4. The RV111 meets these standards with a flow rate of 12,134 CFH for the 2-1/2" pipe size at 2" w.c. pressure drop. The 2-1/2" RV91 flows 5422 CFH at 2" w.c. pressure drop. Therefore, the RV111—2-1/2" is the correct regulator to use.
Example No. 2—To determine maximum recommended operating outlet pressure.
KNOWN: Pipe size 4", flow rate 21,000 CFH, inlet pressure 10" w.c.
3 Dimensions and Spring Ranges
RV81 & 91
RV52 & 53 A RV61 A
A
C C C D B D D B B DIMENSIONS*—inches (millimeters)
Model & RV111 Ven t Swing Call-Outs Illustration Tap Radius A Number ABCD 1/8" 3.6 4.9 3.2 3.25 1.25 RV52 NPT (91) (124) (81) (83) (32) 1/8" 3.9 5.2 3.75 3.9 1.3 RV53 C NPT (99) (132) (95) (99) (33) 1/8" 4.8 6.4 4.4 5.4 1.6 RV61 NPT (122) (164) (111) (138) (41) D 3/8" 6.4 8.4 6 7 2 B RV81 NPT (162) (213) (153) (178) (51) RV91 1/2" 8.5 10.8 6.5 9.1 2.3 RV131 2" pipe NPT (216) (275) (165) (232) (60) RV91 1/4" 8.3 10.5 7.1 9.1 2.4 2.5" pipe NPT (212) (267) (181) (232) (62) A 3/4" 11.5 15.1 9 13.4 3.5 RV111 NPT (284) (373) (229) (324) (89) C 3/4" 18.2 23.25 13.9 18 5.1 RV131 NPT (462) (590) (353) (458) (129)
* Dimensions are to be used only as an aid in designing clearance for the valve. D Actual production dimensions may vary somewhat from those shown.
SPRING SELECTION CHART—inches w.c. (mbar) B
Model A.G.A.CSA Certified Springs Other Springs Available Number
3 to 6 4-8 5-12 1-3.5 2-5 3-8 4-12 RV52 ------(7.5-15) (10-20) (12.5-30) (2.5-9) (5-12.5) (7.5-20) (10-30)
3 to 6 4-8 5-12 1-3.5 2-5 3-8 4-12 RV53 ------(7.5-15) (10-20) (12.5-30) (2.5-9) (5-12.5) (7.5-20) (10-30)
3 to 6 4-8 5-12 1-3.5 2-5 3-8 10- 22 RV61 ------(7.5-15) (10-20) (12.5-30) (2.5-9) (5-12.5) (7.5-20) (25-55)
3 to 6 4-8 5-12 1-3.5 2-5 3-8 4-12 5-15 10- 22 RV81 -- -- (7.5-15) (10-20) (12.5-30) (2.5-9) (5-12.5) (7.5-20) (10-30) (12.5-38) (25-55)
3 to 6 4-8 5-12 1-3.5 2-5 3-8 4-12 5-15 10- 22 RV91 -- -- (7.5-15) (10-20) (12.5-30) (2.5-9) (5-12.5) (7.5-20) (10-30) (12.5-38) (25-55)
3 to 6 4-8 5-12 1-3.5 2-5 3-8 4-12 5-15 10- 22 RV111 -- -- (7.5-15) (10-20) (12.5-30) (2.5-9) (5-12.5) (7.5-20) (10-30) (12.5-38) (25-55)
3 to 6 5-12 2-5 3-8 4-12 10- 22 15- 30 20- 42 RV131 ------(7.5-15) (12.5-30) (5-12.5) (7.5-20) (10-30) (25-55) (38-75) (50-105) NOTE: The area within the heavy line indicates CSA certified springs.
A copyrighted publication of Maxitrol Company 23555 Telegraph Rd., P.O. Box 2230 Southfield, MI 48037-2230 U.S.A. 248.356.1400 • Fax 248.356.0829 www.maxitrol.com European Representatives Warnstedter Strasse 3 06502 Thale, Germany 49.3947.400.0 • Fax 49.3947.400.200 Industriestrasse 1 48308 Senden, Germany 49.2597.9632.0 • Fax 49.2597.9632.99 BULLETIN MI2010-5/00
SAFETY WARNING INSTRUCTIONS INSTRUCCIONES PARA PRECAUCIONES DE FOR MAXITROL GAS PRESSURE REGULATORS SEGURIDAD
NOTE: GAS PRESSURE REGULATORS WILL NOT PARA REGULADORES DE PRESION DE GAS TURN OFF THE FLOW OF GAS. MAXITROL
SPECIAL WARNINGS NOTA: LOS REGULADORES DE PRESION DE GAS IF YOU DO NOT FOLLOW THESE INSTRUCTIONS EXACTLY, A NO CORTAN EL FLUJO DE GAS FIRE OR EXPLOSION MAY RESULT CAUSING PROPERTY DAMAGE, PERSONAL INJURY OR LOSS OF LIFE. ¡PRECAUCIONES ESPECIALES! NO UNTRAINED PERSON SHOULD ATTEMPT TO INSTALL, SI USTED NO SIGUE ESTAS INSTRUCCIONES EXACTAMENTE, MAINTAIN OR SERVICE GAS PRESSURE REGULATORS. PUEDE OCURRIR UN INCENDIO O UNA EXPLOSION, CAUSANDO DAÑOS A LA PROPIEDAD, LESIONES PERSONALES O PERDIDA To minimize the possibility of FIRE, EXPLOSION, and OTHER HAZARDS: DE VIDAS. NADIE QUE NO HAYA SIDO ENTRENADO DEBERA DE TRATAR DE INSTALAR, DAR SERVICIO O DAR MANTENIMIENTO A 1. All products, including gas pressure regulators, used with combustible LOS REGULADORES DE PRESION DE GAS gas must be installed and used strictly in accordance with the instructions of the manufacturer, with government codes and regulations, and plumbing Para reducir la posibilidad de INCENDIO, EXPLOSION Y OTROS RIESGOS: codes and practices. 1. Todos los productos, incluyendo los reguladores de presión de gas, que se 2. Do not use a gas pressure regulator if it appears to have been subjected usan con gases combustibles deberán instalarse y usarse estrictamente de to high temperatures, damaged in any way, or to have been taken apart or acuerdo con las instrucciones del fabricante, usando los códigos y reglamentos tampered with. Any of these may be signs of possible leakage or other gubernamentales así como los códigos y prácticas de plomería. damage that may affect proper operation and cause potentially dangerous 2. No usar un regulador de presión de gas si parece haber estado expuesto a combustion problems altas temperaturas, dañado en alguna forma o que se haya desmantelado o maltratado. Cualquiera de éstas pueden ser señales de posibles fugas u otros 3. daños que pueden afectar el funcionamiento correcto y causar problemas de a. Install the regulator properly with gas flowing as indicated by the arrow combustión potencialmente peligrosos. on the casting. b. Use pipe compound or thread sealant, properly threaded pipes and 3. careful assembly procedure so that there is no cross threading, etc., a. Instalar el regulador correctamente con el gas fluyendo como se indica en la which might cause damage or leakage. flecha en la carcasa de fundición. c. Apply wrench or vise pressure only to the flat areas around the b. Usar un compuesto sellador de tubería o hilo sellador de rosca, tuberías pipe tappings at the end being threaded to the pipe to avoid possible correctamente roscadas y procedimientos de ensamble cuidadoso, asegurándose de que no haya trasroscados, lo cual podría causar daños o fugas. fracture of the regulator body which could result in leakage c. Aplicar únicamente la presión de una llave o tornillo de banco en las áreas planas d. Make sure markings or wording on regulator are not painted over or alrededor de las roscas de la tubería del extremo a enroscar para evitar la posible obliterated. rotura del cuerpo del regulador que podría resultar en fugas. d. Asegurarse de que no se pinten o tachen las marcas o escritura en el regulador. 4. Check carefully for gas leaks immediately after the regulator has been installed and the gas turned on. Do this before attempting to operate the 4. Verificar inmediatamente que no haya fugas de gas después de que el regulador appliance or other gas burning device. Use a rich soap solution (or other haya sido instalado y se haya abierto el paso del gas. Esto deberá hacerse antes de tratar de operar el aparato electrodoméstico o cualquier otro dispositivo accepted leak tester) around the diaphragm flanges, bottom plate, vent quemador de gas. Usar una solución espesa de jabón (u otro probador de fugas opening, seal cap, pipe connections, and all other joints. Wipe clean with a aceptado) alrededor de las bridas del diafragma, el fondo del plato, la apertura de damp rag. It is a good practice to periodically check for leakage during use ventilación, la tapa selladora y las conexiones de la tubería y todas las demás juntas. of the appliance. Absolutely no leakage should occur, otherwise there Limpiar con un trapo húmedo. Es una buena práctica verificar periódicamente que no is a danger of fire or explosion depending upon conditions. Never use haya fugas durante el uso del aparato electrodoméstico. Absolutamente no deberá if leakage is detected. haber ninguna fuga. De otra forma hay peligro de incendio o explosión dependiendo de las condiciones. Nunca deberá usarse si se detectan fugas. CAUTION ¡PRECAUCION! NEVER CONNECT REGULATOR DIRECTLY TO THE PROPANE NUNCA CONECTAR EL REGULADOR DIRECTAMENTE AL SUPPLY SOURCE. MAXITROL REGULATORS REQUIRE AN SUMINISTRO DE PROPANO. LOS REGULADORES MAXITROL EXTERNAL REGULATOR (NOT SUPPLIED). INSTALL THE REQUIEREN UN REGULADOR EXTERNO (NO PROVISTO). EXTERNAL REGULATOR BETWEEN THE PROPANE SUPPLY INSTALAR EL REGULADOR EXTERNO ENTRE EL SUMINISTRO DE SOURCE AND MAXITROL REGULATOR. PROPANO Y EL REGULADOR MAXITROL
5. Very high pressure surges in the gas supply line (or as a result of exposing 5. Aumentos grandes de presión en la línea de suministro de gas (o como resultado de the system to high pressure) may result in serious internal damage and exponer el sistema a alta presión) pueden resultar en daños internos y causar fugas o cause leakage or affect regulator operation. If you suspect that a Maxitrol afectar el funcionamiento del regulador. Si usted sospecha que un regulador Maxitrol ha sido expuesto a más del doble de la presión máxima de entrada, como se muestra en regulator has been exposed to more than twice the maximum operating la tabla siguiente, cierre el paso del gas y haga que el sistema sea verificado por un inlet pressure, as shown in the following chart, turn off the gas and have experto. the system checked by an expert. (over) (a la vuelta)
23555 Telegraph Rd. P.O. Box 2230 Southfield, MI U.S.A. 48037-2230 Phone 248.356.1400 Fax 248.356.0829 www.maxitrol.com 6. Venting must be controlled in accordance with government and plumbing 6. La ventilación deberá estar controlada de acuerdo con los códigos y reglamentos codes and regulations to avoid the danger of escaping gas should there be gubernamentales de plomería para evitar el peligro de que se escape el gas en caso internal leakage. Vent pipes must be open and the open end protected against de una fuga interna. Los tubos de ventilación deberán estar abiertos y el extremo abierto deberá estar protegido contra cualquier materia extraña, incluyendo el agua. entry of foreign matter, including water. 7. La presión de salida del regulador deberá medirse para asegurarse que está de 7. The outlet pressure of the regulator must be measured to make sure it is in acuerdo para el uso que se pretende. Si se necesita cambiar un resorte para accordance with intended usage. If a spring change is required to develop desarrollar la presión de salida requerida, el resorte deberá ser especificado por the required outlet pressure, the spring must be one specified by MAXITROL MAXITROL y la nueva presión de salida deberá anotarse en el regulador.
8. Caution should be used to guarantee that there is sufficient inlet pressure 8. Deberá usarse precaución para garantizar que hay suficiente presión interna para alcanzar la presión de salida deseada y no deberá hacerse ningún reajuste en la to achieve the desired outlet pressure and no readjustment of the outlet presión de salida a menos que la presión interna esté dentro de los límites correctos pressure setting should be made unless the inlet pressure is within the proper para el regulador. Si esto no se lleva a cabo podría resultar en una llama excesiva del limits for the regulator. Failure to follow this may result in overfiring of the aparato electrodoméstico u otro dispositivo quemador de gas. Deberá consultarse el appliance or other gas burning device. The MAXITROL bulletin for the boletín MAXITROL para el regulador para ver la relación específica entre la presión regulator should be consulted for specific inlet and outlet pressure de entrada y la de salida. relationships. 9. Un regulador MAXITROL deberá usarse dentro del rango de temperatura y no deberá excederse la presión máxima de entrada que se muestra en la tabla siguiente 9. A MAXITROL regulator must be used within the temperature range and y deberá estar en la posición indicada de montaje. Los reguladores MAXITROL not in excess of the maximum inlet pressure shown in the following table and pueden usarse con todo tipo de gases combustibles. should be in the mounting position indicated. Maxitrol regulators can be used with all fuel gases. 10. En caso de dudas, favor de comunicarse con el Service Manager (Gerente de Servicio), Maxitrol Company, Southfield, MI USA. Teléfono: 248-356-1400. 10. In case of any doubt, please contact the Service Manager, Maxitrol Company, Southfield, MI USA. Phone: 248/356-1400.
Maximum Operating Mounting Position Inlet Pressure Ambient Temperature Range Model Number [see below] (Presión Máxima de (Rango de Temperatura (Número de Modelo) (Posiciónde Montaje) Entrada para Ambiente) [ver abajo] Operación)
RV12LT, RV20LT 1/2 psi (34 mbar) -40° to 275° F (-40° to 135° C) A, B, C, D
RV20L 2 psi (138 mbar) -40° to 225° F (-40° to 107° C) A, B, C, D
RV47, RV48 (*1) 1/2 psi (34 mbar) 32° to 225° F (0° to 107° C) A, B, C, D, (*1)
RV48T (*1) 1/2 psi (34 mbar) 32° to 275° F (0° to 135° C) A, B, C, D, (*1)
RV52, RV53, (*1) 1/2 psi (34 mbar) -40° to 205° F (-40° to 96° C) A, B, C, D, (*1)
RV61, (*1) 1 psi (69 mbar) -40° to 205° F (-40° to 96° C) A, B, C, D, (*1)
RV81, RV91 1 psi (69 mbar) -40° to 205° F (-40° to 96° C) A only (únicamente)
RV111 1 psi (69 mbar) -40° to 205° F (-40° to 96° C) A only (únicamente)
RV131 2 psi (138 mbar) -40° to 125° F (-40° to 52° C) A only (únicamente)
R400, R500, R600, (*1) 1 psi (69 mbar) -40° to 205° F (-40° to 96° C) A, B, C, D, (*1)
R400S, R500S, R600S, (*1) 5 psi (345 mbar) -40° to 205° F (-40° to 96° C) A, B, C, D, (*1)
R400Z, R500Z, R600Z 1psi (69 mbar) -40° to 205° F (-40° to 96° C) A, B, C, D, (*1)
210D, E, G, J 10 psi (690 mbar) -40° to 205° F (-40° to 96° C) A only (únicamente)
210DZ, EZ, GZ, JZ 5 psi (345 mbar) -40° to 205° F (-40° to 96° C) A only (únicamente)
220D, E, G, J 10 psi (690 mbar) -40° to 205° F (-40° to 96° C) A only (únicamente)
325-3 (*1), 325-5A (*1), 325-7 10 psi (690 mbar) (*1) -40° to 205° F (-40° to 96° C) A, B, C, D, (*1)
(*1) When equipped with a ball-check type automatic (*1) Para estar seguro que el regulador responde con rapidez cuando Mounting Position (Posición de Montaje) vent limiting device (12A04, 12A09, 12A39), regulators está equipado con un dispositivo limitador de ventilación automático A must be in upright position (A) with non-integral vent tipo bola (12A04, 12A09,12A39), los reguladores deberán estar en posición vertical (A) con el limitador de ventilación instalado directamente limiter installed directly into vent threads. Any other a las roscas del tubo de ventilación. Si se usa cualquier otra posición mounting position may interfere with lockup or durante su instalación, esto podrá interferir con el cierre o causar D B B cause pilot outage, where applicable. Maximum inlet que el piloto se apague. La presión máxima de admisión para pressure for regulators with 12A09 or 12A39 is 2 psi reguladores con los dispositivos 12A09 o 12A39 es de 2 psi (gas licuado) Vertical Horizontal (LP) or 5 psi (natural). Inlet pressures exceeding 2 psi o 5 psi (gas natural). Las presiones de admisión que excedan 2 psi Flow C Flow (gas licuado) o 5 psi (gas natural) requerirán una línea de ventilación. (Flujo (Flujo (LP) or 5 psi (natural) require a vent line. Vertical) Horizontal)
LITHO IN U.S.A. 110MMP Installation & Maintenance Instructions MM-217(F)
Series 150 and 157 ¨ (Mercury Switch) Series 150S and 157S (Snap Switch, All Models except 157S-RB-P) Low Water Cut-Off/Pump Controllers For Steam Boilers and Other Level Control Applications
Series 150 and 150S
Typical Applications: Ð Primary or secondary pump controller/ low water fuel cut-off for steam boilers Ð Motorized valve controller Ð Low water cut-off Ð High water cut-off Ð Alarm actuator Series 157 and 157S ! WARNING
N CAUTIO NING ¥ Before using this product read and understand instructions. WAR ¥ Save these instructions for future reference. ¥ All work must be performed by qualified personnel trained in the proper application, instal- lation, and maintenance of plumbing, steam, and electrical equipment and/or systems in accordance with all applicable codes and ordinances. ¥ To prevent serious burns, the boiler must be cooled to 80ûF (27ûC) and the pressure must be 0 psi (0 bar) before servicing. ¥ To prevent electrical shock, turn off the electrical power before making electrical connections. ¥ This low water cut-off must be installed in series with all other limit and operating controls installed on the boiler. After installation, check for proper operation of all of the limit and operating controls, before leaving the site. ¥ We recommend that secondary (redundant) Low Water Cut-Off controls be installed on all steam boilers with heat input greater than 400,000 BTU/hour or operating above 15 psi of steam pressure. At least two controls should be connected in series with the burner control circuit to provide safety redundancy protection should the boiler experience a low water condition. Moreover, at each annual outage, the low water cut-offs should be dismantled, inspected, cleaned, and checked for proper calibration and performance. ¥ ¥ To prevent serious personal injury from steam blow down, connect a drain pipe to the control opening to avoid exposure to steam discharge. ¥ To prevent a fire, do not use this low water cut-off to switch currents over 7.4A, 1/3 Hp at 120 VAC or 3.7A, 1/3 Hp at 240 VAC, unless a starter or relay is used in conjunction with it. Failure to follow this warning could cause property damage, personal injury or death. OPERATION Maximum Pressure: 150 psi (10.5 kg/cm2) Electrical Ratings PumpCircuit Rating (Amperes) Alarm Circuit Rating Motor Horsepower Voltage Full Load Locked Rotor Pilot Duty Voltage Amps Voltage Hp 120 VAC 7.4 44.4 345 VA at 120 VAC 1 120 VAC 1/3 240 VAC 3.7 22.2 120 or 240 VAC 240 VAC 1/2 240 VAC 1/3 Enclosure rating: NEMA 1 General Purpose
Settings and Differential Pressures Values are ± 8” (3.2mm).
Series 150, 150S, 157 and 157S Model 150-MD, 150S-MD, 157-MD and 157S-MD Approximate Approximate Distance Above Distance Above Cast Line Differential Cast Line Differential Pressure Setting In. (mm) In. (mm) Pressure Setting In. (mm) In. (mm) Pump Off 15/16 (24) 0 psi Pump Off 15/16 (24) 0 psi 5/16 (8) 3/8 (16) Pump On 5/8 (16) (0 kg/ Pump On 9/16 (14) (0 kg/ 2 2 Burner On 5/8 (16) cm ) Burner Off 0 (0) N/A cm ) 3/8 (16) 1 Burner Off /4 (6.4) Pump Off 17/16 (37) 150 psi 3/4 (19) Pump Off 13/8 (41) (10.5 kg/ Pump On 11/16 (17) 3/4 (19) 150 psi 5 2 Pump On /8 (16) cm ) Burner Off - 3/8 (-16) N/A (10.5 kg/ 2 Burner On 7/8 (22) cm ) 7/8 (22) Burner Off 0 (0)
150 psi (10.5 kg/cm2) Levels 150 psi (10.5 kg/cm2) Levels
3 1 /8" 113/16" DIFFERENTIAL DIFFERENTIAL PUMP (35mm) NORMAL BOILER (46mm) OFF WATER LINE NORMAL BOILER PUMP WATER LINE BURNER OFF OFF BURNER “CUT-OFF LEVEL” BURNER AT CAST LINE OFF BURNER CUT-OFF LEVEL 3/8" (9.5mm) BELOW CAST LINE 3/4" DIFFERENTIAL (19mm) 3/4" PUMP OFF DIFFERENTIAL (19mm) PUMP ON PUMP OFF PUMP ON
7/8" DIFFERENTIAL (22mm)
BURNER ON BURNER OFF
2 Settings and Differential Pressures (continued) Values are ± 8” (3.2mm).
Model 158/158S Model 158-MD/158S-MD Approximate Approximate Distance Above Distance Above Cast Line Differential Cast Line Differential Pressure Setting In. (mm) In. (mm) Pressure Setting In. (mm) In. (mm) Motorized 15/16 (24) 0 psi Pump Off 15/16 (24) Valve Closed 3/8 (16) 0 psi 5/16 (8) (0 kg/ Pump On 9/16 (14) Motorized 5/8 (16) (0 kg/ cm2) Burner Off 0 (0) N/A Valve Open cm2) Pump Off 17/16 (37) Burner On 5/8 (16) 150 psi 3/4 (19) 3/8 (16) Burner Off 1/4 (6.4) (10.5 kg/ Pump On 11/16 (17) 2 cm ) Burner Off - 3/8 (-16) N/A Motorized 13/8 (41) Valve Closed 150 psi 3/4 (19) Motorized 5/8 (16) (10.5 kg/ 150 psi (10.5 kg/cm2) Levels cm2) Valve Open 7 Burner On /8 (22) 113 16 7/8 (22) / " Burner Off 0 (0) DIFFERENTIAL (46mm) MOTORIZED NORMAL BOILER WATER LINE 2 VALVE 150 psi (10.5 kg/cm ) Levels CLOSED 13/8" BURNER OFF DIFFERENTIAL BURNER CUT-OFF LEVEL (35mm) 3 " MOTORIZED NORMAL BOILER /8 (9.5mm) BELOW VALVE WATER LINE CAST LINE CLOSED BURNER OFF BURNER “CUT-OFF LEVEL” 3 AT CAST LINE /4" DIFFERENTIAL MOTORIZED (19mm) VALVE 3/4" DIFFERENTIAL OPEN CLOSED MOTORIZED (19mm) VALVE CLOSED MOTORIZED VALVE NOTE: Due to the slower operation of some OPEN motorized valves, complete valve opening or closing will occur at slightly different levels than indicated above. 7/8" DIFFERENTIAL (22mm)
BURNER ON BURNER OFF
NOTE: Due to the slower operation of some motorized valves, complete valve opening or closing will occur at slightly different levels than indicated above.
3 Settings and Differential Pressures (continued) Values are ± 8” (3.2mm).
Model 159/159S Approximate Distance Above Cast Line Differential Pressure Setting In. (mm) In. (mm)
Pump #1 Off 15/16 (24) 0 psi 5/16 (8) Pump #1 On 5/8 (16) (0 kg/ 2 Pump #2 Off 5/8 (16) cm ) 3/8 (16) Pump #2 On 1/4 (6.4)
Pump #1 Off 13/8 (41) 150 psi 3/4 (19) Pump #1 On 5/8 (16) (10.5 kg/ 2 Pump #2 Off 7/8 (22) cm ) 7/8 (22) Pump #2 On 0 (0)
150 psi (10.5 kg/cm2) Levels
13/8" DIFFERENTIAL (35mm) NORMAL BOILER PUMP #1 WATER LINE OFF PUMP #2 ON PUMP #2 ON AT CAST LINE
3/4" DIFFERENTIAL (19mm) PUMP #1 NORMAL BOILER OFF WATER LINE PUMP #1 ON
7/8" DIFFERENTIAL (22mm) PUMP #2 OFF PUMP #2 ON PUMP #2 ON AT CAST LINE
4 INSTALLATION
TOOLS NEEDED: IMPORTANT: Follow the boiler manufacturer's Two (2) pipe wrenches, one (1) flathead screw instructions along with all applicable codes and driver, and pipe sealing compound. ordinances for piping, blow down valve and water gauge glass requirements.
STEP 1 - Determine the Elevation at Which the Low Water Cut-Off/Pump Controller Must be Installed
STEAM EQUALIZING PIPE If the control will be the primary low water fuel cut-off, size the steam (top)
and water (bottom) equalizing pipe lengths 13/8" AS A PRIMARY so that the horizontal cast line on the body (35mm) LOW WATER CUT-OFF/PUMP CONTROLLER is 1a” (35mm) below the boiler’s normal NORMAL BOILER WATER LINE
water level, but not lower than the low- LOWEST PERMISSIBLE BURNER “CUT-OFF LEVEL” AT CAST LINE est, safe permissible water level, as WATER LEVEL determined by the boiler manufacturer. WATER VERTICAL EQUALIZING PIPE EQUALIZING PIPE OR
BLOW DOWN VALVE If the control will be the secondary low water fuel cut-off, size the steam (top) and water (bottom) equalizing pipe lengths so STEAM EQUALIZING PIPE that the horizontal cast line on the body is at or above, the lowest, safe permissi- AS A SECONDARY ble water level, as determined by the LOW WATER CUT-OFF/PUMP CONTROLLER boiler manufacturer. BURNER OFF
LOWEST PERMISSIBLE WATER LEVEL BURNER “CUT-OFF LEVEL” AT CAST LINE
WATER VERTICAL EQUALIZING PIPE EQUALIZING PIPE
BLOW DOWN VALVE
STEP 2 - Installing the Low Water Cut-Off
a. Using a pipe wrench, unscrew the plastic float blocking plug (A) from the low water cut-off body (B).
Series 150 and 150S Models 150-B and 150S-B Series 157 and 157S (except Model 150-B and 150S-B) A A B
A B B
5 b. For Models 150-B and 150S-B and Series Models 150-B and 150S-B Series 157 and 157S 157 and 157S (For all other models, proceed to Step 3). C A C Screw the w” NPT steel plug (C) (provided) in tapping (A). A ! CAUTION The plug must be reinstalled before control is shipped installed on the boiler, and removed when boiler is installed after shipment. Failure to follow this caution may damage float and operating mechanism.
c. Mount and pipe the low water cut-off (D) on a vertical equalizing pipe (E) at the required E elevation level, as determined in Step 1.
Install a full ported blow down valve (G) directly below the lower cross of the water D equalizing pipe (F).
Note: 1” NPT tappings are provided, with F the exception of some 157 and 157S mod-
els which are 14” NPT. G
STEP 3 - Installing a Water Gauge Glass (Required on all steam boilers)
a. Install a water column (H) (not Series 157 and 157S All Other Models included with product) for all mod- els except Series 157 and 157S (with integral water column). J H
J b. Install a water gauge glass (J). Note: Gauge glass and tri-cocks not included with product.
6 STEP 4 - Electrical Wiring ! WARNING ¥ To prevent a fire, do not use this product to switch currents over 7.4A, 1/3 Hp at 120 VAC or 3.7A, 1/3 Hp at 240 VAC, unless a starter or relay is used in conjunction with it. ¥ To prevent electrical shock, turn off the electrical power before making electrical connections. ¥ This low water cut-off must be installed in series with all other limit and operating controls installed on the boiler. After installation, check for proper operation of all of the limit and operating controls, before leaving the site. ¥ Modification of the switch assembly before or after installation could cause damage to the boiler and/or boiler system. Failure to follow this warning could cause electrical shock, an explosion and/or a fire, which could result in property damage, personal injury or death. Switch Operation
For all Models except 158/158S and 159/159S
Boiler feed pump off, Boiler feed pump on, Boiler feed pump on, burner on, alarm off. burner on, alarm off. burner off, alarm on.
1 2 4 5 6 1 2 4 5 6 1 2 4 5 6
For Models 158 and 158S
Motorized valve closed, Motorized valve open, Motorized valve open, burner on, alarm off. burner on, alarm off. burner off, alarm on.
1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6
For Models 159 and 159S
Pump #1 off, Pump #1 on, Pump #1 on, pump #2 off. pump #2 off. pump #2 on.
1 2 5 6 1 2 5 6 1 2 5 6
a. Using a flathead screwdriver, remove the K junction box cover (K).
7 b. Following the appropriate wiring diagram, (refer to page 9) based on your application require- IMPORTANT: There must be ments, and using BX armored cable or Thinwall a minimum space of 1/2” electrical metal tubing connector fittings, make (13mm) between connector fittings and electrical live electrical connections to the junction box (L). metal parts. Snap Switches (Series 150S and 157S)
PUMP ALARM LOW WATER PUMP #1 PUMP #2 MOTORIZED ALARM LOW WATER CIRCUIT CIRCUIT CUT-OFF CIRCUIT CIRCUIT VALVE CIRCUIT CUT-OFF TERMINALS TERMINALS TERMINALS TERMINALS TERMINALS TERMINALS TERMINALS TERMINALS
1 23456
L L L MOTORIZED PUMP VALVE PUMP #1 SWITCH LOW WATER LOW WATER SWITCH SWITCH PUMP #2 CUT-OFF AND CUT-OFF AND SWITCH ALARM SWITCH ALARM SWITCH
Automatic Reset Automatic Reset Automatic Reset (All models except 158S and 159S) Model 158S Model 159S
PUMP ALARM LOW WATER PUMP ALARM LOW WATER CIRCUIT CIRCUIT CUT-OFF CIRCUIT CIRCUIT CUT-OFF TERMINALS TERMINALS TERMINALS TERMINALS TERMINALS TERMINALS
L L
PUMP PUMP SWITCH LOW WATER SWITCH LOW WATER CUT-OFF AND CUT-OFF AND ALARM SWITCH ALARM SWITCH
Manual Reset Manual Reset (All models except 158S) Model 158S-M
Mercury Switches (Series 150 and 157)
TO TO TO PUMP ALARM LOW WATER ELECTRIC LOW WATER LOW WATER CIRCUIT CIRCUIT CUT-OFF NO. 1 PUMP NO. 2 PUMP VALVE ALARM CUT-OFF TERMINALS TERMINALS TERMINALS CIRCUIT CIRCUIT
1 23456 1 256
L L L CUT-OFF PUMP AND ALARM SWITCH SWITCH
(All models except 158 Model 158 Model 159 and 159)
8 WIRING DIAGRAMS For Motorized Valves, refer to the valve manufacturer's wiring instructions. Low Water Cut-Off Only 1. Main Line Switch - For burner circuits within the 2. Pilot Switch - To holding coil of a starter when switch’s electrical rating. the burner circuit exceeds the switch’s electrical rating.
LINE
LINE LOAD OR
12 456
12 456 LOAD
Pump Control Only 1. Main Line Switch - For pump motors within the 2. Pilot Switch - To holding coil of a starter when switch’s electrical rating. the pump circuit exceeds the switch’s electrical rating.
LINE LINE LOAD
OR 12 456
Note: For Models 159 and 159S, use terminals 12 456 5 and 6 for pump #2. LOAD
Alarm Circuit Only 1. Low Water Alarm 2. High Water Alarm
ALARM ALARM OR NEUTRAL NEUTRAL
HOT HOT 12 456 12 456
Combination Pump Control, Low Water Cut-Off and Alarm 1. Main Line Switch - For burner circuits within 2. Pilot Switch - To holding coil of a starter when the switch’s electrical rating. the burner circuit exceeds the switch’s electrical rating.
SEE PUMP ALARM LINE (3 PHASE) SEE PUMP CONTROL CONTROL HOT CIRCUIT CIRCUIT ALARM OR
TO NEUTRAL 12 456 TO BURNER CONTROL CIRCUIT 12 456 LOAD
9 6. Re-attach the junction box cover (K). K
Note: Cover must be installed correctly as shown
STEP 5 - Testing
This control is factory calibrated for specific applications. The following testing procedure is only meant to serve as a verification of proper operating sequence. Dimensions provided are typical for a boiler not being fired and/or not at pressure. Actual operating ranges are shown on page 2 in the "Operation" section.
IMPORTANT: Follow the boiler manufacturer’s start-up and operating instructions along with all applicable codes and ordinances. Note: Water levels stated below are only for 150 psi (10.5 kg/cm2) operation.
a. Turn on the electric power to the boiler. With the boiler empty the pump should go on and the burner must remain off. ON
! WARNING OFF If the burner comes on, immediately turn the boiler off and make the necessary corrections. Failure to follow this warning could cause an explosion or fire and result in property damage, personal injury or death.
b. The boiler should begin to fill with water. Watch the gauge glass (J) until the water J level reaches approximately d” (22mm) above the horizontal cast line (M) on the low water cut-off. IMPORTANT: If water does not start filling the M 7/8" boiler, immediately turn off the the boiler and (22mm) make the necessary corrections.
10 c. For automatic reset models only. When the water Snap Switch Models level reaches approximately d” (22mm) above the horizontal cast line (lower for MD models) the burner should come on (pump #2 should shut off with Models 159 and 159S). N
OR
For manual reset models only. When the water d level reaches approximately ” (22mm) above the Mercury Switch Models horizontal cast line press the reset button (N). The burner should then come on. N
d. Continue watching the gauge glass (J) to see that the water continues to rise to J approximately 1a” (35mm) (17/16” (37mm) for MD models) above the horizontal cast line (M). The pump should shut off (the motorized valve should close with Models M 7/8" 158 and 158S, or with Models 159 and (22mm) 159S, pump #1 should shut off).
! CAUTION To prevent serious personal injury from steam pipe blow down, connect a pipe to avoid exposure to steam discharge. Failure to follow this caution could cause personal injury. e. Blow down the control when the water in the boiler is at its normal level and the burner is on. Follow Blow Down Procedure found in Maintenance Section on the last page of these instructions.
INSTALLATION COMPLETE
11 MAINTENANCE
SCHEDULE: BLOW DOWN PROCEDURE: ¥ Blow down control as follows when boiler is in operation. CAUTION Ð Daily if operating pressure is above 15 psi. ! Ð Weekly if operating pressure is below 15 psi. To prevent serious personal injury from steam pipe blow down, connect a drain pipe to the control opening to avoid exposure to steam NOTE discharge. More frequent blow-down may be necessary due Failure to follow this caution could cause to dirty boiler water and/or local codes. personal injury.
¥ Disassemble and inspect annually. Replace Blow down the control when the water in the boiler the low water cut-off/pump controller if it is is at its normal level and the burner is on. Slowly worn, corroded, or if components no longer open the upper then the lower blow-down valves operate properly. and observe the water level fall in the sight glass. ¥ Inspect the float chamber and equalizing piping Close the valves (lower first then upper) after annually. Remove all sediment and debris. verifying that the pump contacts have closed and ¥ Replace head mechanism every 5 years. the burner shuts off. If this does not happen, More frequent replacement may be required when immediately shut off the boiler, correct the prob- severe conditions exist such as rapid switch cycling, lem and retest. surging water levels, and use of water treatment For Models 158 and 158S, close the blow down chemicals. valve after the motorized valve opens and the ¥ We recommend head mechanism replacement burner shuts off. For Models 159 and 159S, close when the switch(es) no longer operate properly. the blow down valve after both pumps come on. If If you choose to replace the switch(es), order the this does not happen, immediately shut off the proper McDonnell & Miller replacement switch or boiler and correct the problem. switch assembly and follow the Repair Procedure provided.
2-Wire 3-Wire Pump Burner Replacement Replacement Switch Assembly Mercury Tubes Valve #1
CAUTION ! Valve #2 Snap switches must be replaced as an assembly.
3500 N. Spaulding Avenue Chicago, Illinois 60618 tel: 773 267-1600 fax: 773 267-0991 www.mcdonnellmiller.com
©2003 ITT Industries Inc. Printed in U.S.A. 10-03 210341 Form 261 Sheet P/N 100204-1 Rev. H Warrick® Series 26M Controls Installation and Operation Bulletin
This bulletin should be used by experienced personnel as a guide to the installation of series 26M controls. Selection or installation of equipment should always be accompanied by competent technical assistance. We encourage you to contact Gems Sensors or its local representative if further information is required.
Specifications Installation Control Design: Solid State components enclosed in clear lexan plug-in style housing. Housing carries no NEMA ratings. 1. Install octal socket in appropriate enclosure using two #6 or #8 metal screws. Contact Design: SPDT (1 form C): One normally open (N.O.) and one normally closed (N.C.) powered contacts. 1A. Install rail mount socket on appropriate Contact Ratings: 10 A @ 120,240 VAC resistive (120°F), 1A @ rail (DIN mount) in appropriate enclosure if 120, 240 VAC resistive (150°F), 1/3 H.P. @ 120, 240 VAC (120°F) applicable. Contact Life: Mechanical- 5 million operations Electrical- 2. Wire control per wiring diagram, following 100,000 operations minimum at rated load. N.E.C. and local codes Supply Voltage: 120, 240 or 24 VAC models: +10% -15% 50/ 60 Hz. 208/240 model: 187 Vmin to 255 Vmax. VAC 50/60Hz 3. Install control module in socket. Supply Current: Relay energized at 4.4 VA Secondary Circuit: 12 VAC RMS Voltage on probes. 1.5 Sensitivities vs Maximum milli-amp Current. Probe Wire Distance*
Sensitivity: Models operate from 4.7K to 100K maximum SENSITIVITY SENSITIVITY DISTANCE specific resistance. CHARACTER (KOHMS) (FT) Temperature: -40 TO 150°F ambient A 4.7 900 Terminals: All connections #6-32 screw type terminals with pres- B 10 600 sure clamps. C 26 250 Time Delays: Standard – LLCO probe, 3 seconds standard for D 50 100 lowering level. E 100 50 Listings: U.L. limit control recognition (353). 240 and 208 volt * Based on type MTW or THHN units are not U.L. limit control recognized. wire, #14 or #16 Awg
Dimensional Diagram
2-3/8”
2-5/16”
1-5/32”
2-3/4” 2.0”
3-1/2” 1-11/16”
11/64” Dia.
5/8” Wiring Diagram Options: AC Power Automatic Reset: (Reset terminals not used): When the liquid rises to the electrode Reset on terminal 6, the control energizes, chang- ing state of the load contacts. (LED will be L1 NC lit) The control remains energized until the liquid level recedes below electrode on ter- NO minal 6. The control then de-energizes, (LED 1 2 11 will not be lit) returning load contacts to origi- L2 10 nal state. Unless otherwise specified, there
3 is a three second time delay on decreasing 9 level. Liquid must be below probe on termi- 4 8 5 6 7 nal 6 for a full three seconds before control de-energizes. Manual Reset : (Normally closed pushbutton installed across terminals #7 G LWCO and #8): When the liquid rises to the elec- Low Level Cut-0ff Probe trode on terminal 6, the control will remain Reference Probe IF METALLIC, TANK MAY BE USED de-energized until the pushbutton is de- INSTEAD OF REFERENCE PROBE pressed. The control will then energize, (LED will be lit) changing the state of the con- tacts. The control remains energized until the liquid level recedes below electrode on terminal 6. The control then de-energizes, (LED will not be lit) returning load contacts to their original state. Unless otherwise specified, there is a three second time delay on decreasing level. Liquid must be below probe on terminal 6 for full three seconds before control de-energizes. Manual Reset with Optional Power Outage Feature: (Normally closed pushbutton across reset terminals) Con- trol will ignore power loss to control. With liquid above electrode on terminal 6, a power outage will cause the control to de-energize, but will automatically energize upon return of power. However, loss of liquid will cause control to de-ener- gize and remain so until liquid again rises to electrode and pushbutton is depressed. Dirty Electrode Detection: The LED will flash every half-second once the probe resistance reaches a value greater than the nominal control sensitivity rating. The relay state will not change until it exceeds the nominal sensitivity by more than 25% (typically) at nominal input voltage. At which time the LED and relay contact return to the dry state. Such a condition may suggest electrode maintance is required. Test Feature Allows LLCO circuit to be tested. Holding down the reset button for 3 seconds will allow the LLCO circuit to trip which simulates the loss of water, without the need of draining the water level in the boiler. The control will return to normal operation once the reset button is pressed a second time.
26M X X X X X XX XX X Optional Character Chart Dirty Probe: Blank = No Dirty Probe, A = With Dirty Probe
Time Delay Increasing Level: 00-90 seconds. Blank = 0 seconds N.C. Power Test Pushbutton Outage Feature Time Delay Decreasing Level: 03-90 seconds. Blank = 3 seconds
Optional Character: Optional character chart A X X X
Enclosure: 0=None, 1=NEMA 1, 4=NEMA 4 B X C X Socket Style: A=11 Pin Octal, B=DIN mount, M=None,module only E X Supply Voltage: 1=120VAC, 2=240VAC, 3=24VAC, 8=208/240VAC F X X Sensitivity : A=4.7K, B=10K, C=26K, D=50K, E=100K Y X X Z X X X No Option
Gems Sensors Inc. One Cowles Road Plainville, CT 06062-1198 Tel: 860-793-4579 Fax: 860-793-4580